Insulating Bobbin Grooves for Slot Insulation Insertion
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Solution Overview
Problem
Existing coil insulating structures in electromagnetic motor stators face challenges in securing sufficient electrical insulation distance between the coil and stator core, particularly in small motors, due to insufficient creepage distance and the need for manual insertion of insulating sheets, which complicates the molding process and reduces the coil's occupation area.
Innovation Solution
The formation of opposing groove portions in the slot opening portion side of the insulating member allows for easy insertion of an electrically insulating sheet, enhancing workability and maintaining uniform thickness, thus securing the electrical insulation distance without negatively affecting the molding of the insulating member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a step structure is provided in the insulating member to facilitate insulating sheet insertion, then the insulating sheet is easy to insert, but the insulating member becomes difficult to mold and breaks easily
Solution Approach 1:
The insulating member is segmented by providing groove portions that divide the structure into regions, allowing the insulating sheet to be inserted along the grooves without requiring complex step structures. This segmentation facilitates insertion while preserving the overall structural integrity and moldability of the insulating member.
Solution Approach 2:
The groove portions act as intermediaries that guide the insulating sheet into the correct position between the coil and stator core. Instead of modifying the insulating member with protruding steps, the grooves provide a pathway that mediates the insertion process, making both insertion easier and molding feasible.
2Manufacturing precision
If a coil position regulating protrusion is formed integrally with the slot insulating member, then the winding position is regulated, but the occupation area of the coil is suppressed
Solution Approach 1:
The coil position regulating function is extracted from the insulating member structure. Instead of forming an integrally attached protrusion that occupies coil space, the regulation is achieved through the groove portions in the insulating member that guide the coil position without physical protrusions into the coil winding area.
3Extent of automation
If the slot opening portion is left open for automatic winding, then the winding process is automated, but the creepage distance and spatial distance between coil and stator core are insufficient
Solution Approach 1:
The insulating sheet is preliminarily positioned using the groove portions in the insulating member before the coil winding is completed. This preliminary action ensures that the electrical insulation distance is established in advance, maintaining reliability while allowing the slot opening to remain open for automated winding operations.
Data Source
AI summary
A coil is wound via an electrically insulating member within a slot of a stator core of an electromagnetic motor which is formed of a stator and a rotor. Groove portions are formed to oppose one another in respective opposing portions of a slot opening portion side of the electrically insulating member. An electrically insulating sheet is disposed by being inserted into the pair of groove portions.