Brushless DC Motor Stator Winding with Single Continuous Wire
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Solution Overview
Problem
The assembly of brushless direct current motors is complicated due to the need for multiple conductive wires, leading to high fabrication costs and loose connections, as existing methods require soldering and excessive wire cutting.
Innovation Solution
A stator part with a single conductive wire wound uninterruptedly around stator poles, eliminating the need for soldering and reducing the number of wire parts to be fixed, using a winding method that connects the wire ends to simplify the assembly and reduce costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple conductive wires are used for stator windings, then the motor can function properly, but the assembly structure becomes complicated and fabrication cost increases
Solution Approach 1:
The patent merges multiple separate conductive wires into a single continuous conductive wire that forms all stator windings. This single wire is wound around multiple stator poles in sequence, eliminating the need for multiple separate wires and their associated terminals, thereby simplifying the assembly structure while maintaining proper motor function.
Solution Approach 2:
The single conductive wire performs multiple functions: it forms windings around multiple stator poles, provides electrical connections between all poles, and eliminates the need for separate terminal connections. This multi-functional design reduces the number of components and simplifies the overall assembly.
2Ease of manufacture
If multiple conductive wires with many terminals are used, then the motor can be assembled, but loose connection of conductive wires容易发生 and additional glues are needed
Solution Approach 1:
By combining multiple wired connections into a single continuous wire, the patent eliminates multiple potential connection points where loose connections could occur. The single wire design removes the need for soldering multiple separate terminals and eliminates the requirement for additional glues to secure wire connections.
3Quantity of substance
If three conductive wires are used for stator windings, then the windings can be formed, but excessive wire parts need to be cut off leading to waste
Solution Approach 1:
The single conductive wire is pre-formed with the complete winding path around all stator poles before installation. This preliminary formation of the entire winding path eliminates the need for cutting and trimming excessive wire parts after assembly, thereby reducing material waste.
Data Source
AI summary
A brushless direct current motor, a stator part and its winding method are provided. The stator part includes a stator core and stator windings wound around stator poles. The stator poles and the stator windings are arranged in a one-to-one correspondence with each other. The stator windings are formed by winding a single conductive wire uninterruptedly on the stator poles. Two ends of the conductive wire are connected.