Armature Connecting Insulator Guide Portion Interference

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Solution Overview

Problem

Existing armatures face challenges in designing guide portions that do not interfere with each other, particularly due to complex shapes and increased size, which complicates the arrangement of core constituent members and insulators.

Innovation Solution

The armature features a connecting insulator member with a lower, intermediate, and upper layer insulator member, each with arc-shaped guide portions arranged in a specific axial and radial configuration to prevent interference, allowing for the easy realization of non-interfering guide portions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If guide portions are arranged to connect two insulators spaced apart in the circumferential direction, then jumper wire guidance is achieved, but guide portions may interfere with each other

Engineering Contradiction:
Improvejumper wire guidanceVSAvoidguide portion arrangement
Core Design Contradiction:
Ease of operationVSDevice complexity

Solution Approach 1:

The patent transitions from a two-dimensional planar arrangement of guide portions to a three-dimensional spatial arrangement by stacking insulator members in the axial direction. Each insulator member has guide portions at different axial positions, allowing jumper wires to be routed at multiple levels without interference. This dimensional change resolves the contradiction by enabling effective wire guidance while avoiding guide portion interference.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

2Device complexity

If multiple insulator members are assembled in the axial direction, then guide portion interference is prevented, but radial and axial enlargement occurs

Engineering Contradiction:
Improveguide portion interference preventionVSAvoidarmature size
Core Design Contradiction:
Device complexityVSVolume of moving object

Solution Approach 1:

The patent divides the insulator structure into multiple discrete insulator members stacked in the axial direction, with each member having its own guide portions. This segmentation allows the guide portions to be distributed at different axial levels, preventing interference while maintaining a compact overall structure. The segmented approach resolves the contradiction by organizing guide portions spatially without requiring excessive radial or axial expansion.

Inventive Principle:
Principle #1Segmentation

3Strength

If arc-shaped guide portions are used, then structural rigidity is enhanced, but manufacturing complexity increases

Engineering Contradiction:
Improveguide portion rigidityVSAvoidarc shape fabrication
Core Design Contradiction:
StrengthVSEase of manufacture

Solution Approach 1:

The patent employs arc-shaped guide portions instead of straight or angular configurations. The curved geometry inherently provides structural rigidity and resistance to deformation while distributing mechanical stresses more evenly. Although curved shapes can be more challenging to manufacture, the arc configuration achieves superior mechanical performance that resolves the contradiction between strength and manufacturability by prioritizing the critical rigidity requirement.

Inventive Principle:
Principle #14Spheroidality (Curvature)

Data Source

PatentUS11387691B2Armature
Publication Date: 2022.07.12 DENSO CORP
  • US11387691B2 patent drawing
  • US11387691B2 patent drawing
  • US11387691B2 patent drawing

AI summary

A stator includes a connecting insulator member having a guide portion that connects two insulators, and jumper wires that are guided by the guide portion and connect two coils. The connection insulator member includes a lower layer insulator member, an intermediate layer insulator member, and an upper layer insulator member. The guide portion of the lower layer insulator member has a lower layer arc connecting part, the guide portion of the intermediate layer insulator member has an intermediate layer arc connecting part, and the guide portion of the upper layer insulator member has an upper layer arc connecting part. The intermediate layer arc connecting part is arranged above in the axial direction with respect to the lower layer arc connecting part in the axial direction, and the upper layer arc connecting part is arranged outside in the radial direction with respect to the intermediate layer arc connecting part.