Brushless Motor Stator Insulator Layout for Bidirectional Rotor Insertion
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Solution Overview
Problem
In brushless motors, the design where all connecting rings are arranged at one axial side of the stator with an inner diameter less than the rotor's outer diameter restricts rotor insertion, requiring insertion from the opposite side, limiting assembly flexibility and efficiency.
Innovation Solution
The design is modified to allow connecting rings with an inner diameter greater than the rotor's outer diameter, enabling insertion from both axial sides, and arranging them radially between the stator core and rotor to utilize space effectively, while maintaining a compact stator size by aligning them axially and positioning bridging wires outside the connecting rings to prevent interference during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If all connecting rings are arranged at one axial side of the stator with inner diameter less than the rotor's outer diameter, then the stator structure is compact, but the rotor insertion is restricted to one side only
Solution Approach 1:
The insulators are divided into multiple insulating parts, each with its own connecting ring. This segmentation allows the connecting rings to be distributed at different axial positions rather than concentrated at one side, enabling rotor insertion from either axial side while maintaining structural organization.
Solution Approach 2:
The connecting rings are arranged in the axial dimension at different positions rather than being confined to one side. By utilizing the axial dimension for distributed placement, the design enables bidirectional rotor insertion without significantly increasing radial or circumferential dimensions.
2Productivity
If connecting rings are arranged radially between the stator core and rotor, then space is utilized effectively, but the stator size may increase
Solution Approach 1:
The connecting rings are positioned at specific axial locations where they connect insulating parts, rather than being uniformly distributed. This localized placement optimizes space utilization while minimizing the overall axial length of the stator by avoiding unnecessary extensions.
Solution Approach 2:
The connecting rings are nested within the radial space between the stator core and rotor, utilizing the existing radial gap rather than requiring additional axial space. This nesting approach allows effective space utilization without proportionally increasing the stator's axial dimension.
3Reliability
If bridging wires are positioned outside the connecting rings, then interference during assembly is prevented, but the winding structure becomes more complex
Solution Approach 1:
The bridging wires are extracted from the region inside the connecting rings and positioned outside them. This separation eliminates interference between bridging wires and connecting rings during assembly while maintaining the electrical connectivity function of the windings through alternative routing paths.
Data Source
AI summary
A stator includes a stator core, a plurality of windings and a plurality of insulators. The stator core is constituted of a plurality of core constituent parts each of which includes a yoke constituent part and a tooth protruding from the yoke constituent part. Each of the windings has a plurality of winding sections each of which is wound around a corresponding one of the teeth of the stator core. Each of the insulators has a plurality of insulating parts, each of which is mounted to a corresponding one of the core constituent parts to insulate the tooth included in the corresponding core constituent part and the winding section wound around the tooth from each other, and a connecting ring that connects the insulating parts. Each of the connecting rings of the insulators has an inner diameter set to be greater than an outer diameter of a rotor.