Stepping Motor Coil Assembly Slack Formation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming a slack in coil wires during the assembly of stepping motors are complex, prone to breaking the terminal block, and can lead to variations in pitch and assembly difficulties, increasing costs and reducing workability.
Innovation Solution
A coil assembly with flange portions and terminal pin embedding portions, where a concave portion allows a slack forming pin to be inserted and pulled out, creating a slack portion that conforms to the shape of the pin, preventing breakage and protrusion, and facilitating operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal block is pushed outwardly in radial direction by the stator part to form a slack, then a slack can be formed in the coil wire near the terminal pin, but the operation becomes complicated and there is a risk of breaking the terminal block due to excessive deformation
Solution Approach 1:
The concave portion is pre-formed in the terminal block at the position where the slack portion of the coil wire should be located. This preliminary structural preparation allows the slack to be naturally formed when the coil wire is wound, eliminating the need for complex post-assembly deformation operations and reducing the risk of terminal block breakage.
Solution Approach 2:
The invention uses a simple concave portion structure that is easily formed in the terminal block, replacing complex deformation mechanisms. The concave portion serves as a temporary guide structure that facilitates slack formation without requiring expensive or complex assembly equipment.
2Reliability
If the stator part is contacted inside the terminal block from an oblique direction to press the terminal block outwardly, then a slack can be formed, but variation of sizes of parts causes inclination of the terminal block to vary, thereby varying pitch between terminal pins, and it may be difficult to insert the terminal pin into a hole of a circuit board
Solution Approach 1:
The concave portion is specifically designed at the exact location where the slack portion needs to be formed, between specific terminal pin embedding portions. This localized structural feature ensures that only the specific coil wire section requiring slack is affected, while other terminal pins maintain their original positions and pitch accuracy.
Solution Approach 2:
The concave portion is pre-formed in the terminal block during manufacturing, establishing the correct geometry before assembly. This preliminary action ensures that when the coil wire is wound, the slack portion naturally conforms to the concave portion shape without causing displacement of terminal pins, thereby maintaining pitch precision.
3Reliability
If a slack is provided in the coil wire near the terminal pin, then the risk of coil wire breaking is reduced, but the slack portion may protrude and be involved with the coil wire during winding, or gyrate due to centrifugal force blocking winding
Solution Approach 1:
The concave portion acts as an intermediary structure that receives and contains the slack portion of the coil wire during the winding process. This intermediary structure prevents the slack portion from interfering with the winding operation while still providing the necessary slack to reduce wire stress and breakage risk.
Solution Approach 2:
The concave portion is strategically positioned to accommodate only the slack portion of the coil wire at the specific location between terminal pins. This localized containment allows the slack to exist without protruding into the winding path, preventing interference with the coil winding process while maintaining wire reliability.
Data Source
AI summary
A coil assembly in which a slack can be formed in a coil wire without increasing assembly cost, and a stepping motor using the same, are provided; the coil assembly includes a bobbin 232 having flange portions 233 and 234 at both ends thereof, multiple terminal pin embedding portions 235a arranged at one flange portion 234, a terminal pin 236 embedded in the terminal pin embedding portion 235a, and a coil 231 of which an end portion of coil wire 237 is entwined around the terminal pin 236, the coil wire 237 wound around the bobbin 232, in which a concave portion 238 which concaves to a radial direction of the bobbin 232 and penetrates to an axial direction of the bobbin 232 is formed between the terminal pin embedding portions 235a, the coil wire 237 exists from a base portion of the terminal pin 236, passes through the concave portion 238, started to be wound around the bobbin 232, and has a slack portion 237a which exists in the concave portion 238.