Coil Bobbin Design for Stator Core Protection and Assembly
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Solution Overview
Problem
Existing methods for reducing iron loss and improving assembly reliability in distributed winding radial gap-type rotating electric machines face challenges, such as stress application to stator cores and increased man-hours, while maintaining high positional accuracy and preventing iron loss deterioration.
Innovation Solution
A coil bobbin with a teeth holding portion and slot insulator, made of insulating materials, that covers the stator core's circumferential and axial side surfaces, featuring through-holes for easy coil conductor insertion and assembly, reducing stress on the core and enhancing positional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If high-performance soft magnetic materials (amorphous metal, finemet, nanocrystalline material) are used to reduce iron loss, then iron loss is reduced, but manufacturing cost increases due to extremely thin plate thickness (0.025 mm) and high hardness (900 Vickers hardness)
Solution Approach 1:
The patent uses conventional electromagnetic steel sheets instead of expensive high-performance materials like amorphous metal or nanocrystalline materials. This substitution with cheaper, more manufacturable materials resolves the contradiction between reducing iron loss and maintaining ease of manufacture, while still achieving acceptable performance through optimized coil bobbin design and assembly methods.
Solution Approach 2:
The patent changes the material selection parameters from extreme thinness (0.025 mm) and high hardness (900 Vickers) to conventional electromagnetic steel sheet specifications that are easier to manufacture. This parameter change allows standard manufacturing processes to be used, reducing cost while maintaining functional performance through design optimization.
2Quantity of substance
If rectangular wire coil is used to increase space factor in slot, then space factor is improved, but coil end volume increases due to complicated connection structure
Solution Approach 1:
The patent segments the coil structure into modular components with standardized connection interfaces. By dividing the coil assembly into manageable segments with simplified connection points, the complicated connection structure is reduced, thereby decreasing coil end volume while maintaining the space factor benefits of rectangular wire coils in the slot.
Solution Approach 2:
The patent optimizes the spatial arrangement of coil connections by utilizing three-dimensional space more efficiently. Through dimensional optimization of the connection structure, the coil end volume is reduced while the rectangular wire configuration maintains its space factor advantage within the slot area.
3Reliability
If welding method is used to connect coil ends, then connection is achieved, but stress is applied to stator core and slot insulator is damaged during bending
Solution Approach 1:
The patent introduces a coil bobbin as an intermediary component that facilitates coil connection without requiring direct welding of coil ends. The coil bobbin serves as a mediating structure that holds and positions conductors, eliminating the need for stress-intensive bending and welding operations that would otherwise damage the stator core and slot insulator, while still achieving reliable electrical connections.
Solution Approach 2:
The patent replaces the mechanical welding and bending process with a non-contact or low-stress insertion method using the coil bobbin structure. This substitution eliminates the harmful mechanical stresses applied during traditional welding operations, preventing damage to the stator core and slot insulator while maintaining connection reliability through precise positioning and electrical contact.
4Object-affected harmful factors
If V-shaped combining portions are used to join conductors, then welding is eliminated, but assembly complexity increases due to need for conductive paste adhesive application
Solution Approach 1:
The patent extracts the connection function from complex V-shaped combining portions requiring adhesive application. By removing this complicated joining mechanism and replacing it with the simplified coil bobbin insertion structure, the assembly process becomes less complex while still achieving reliable conductor connections without welding or adhesive materials.
Data Source
AI summary
A coil bobbin of the present disclosure is a coil bobbin attached to a stator core of a distributed winding radial gap-type rotating electric machine, and includes a teeth holding portion and a slot insulator which are made of an insulator. The teeth holding portion has: a first wall surface that covers a first circumferential side surface of a tooth of the stator core; a second wall surface that covers at least a part of a second circumferential side surface of the tooth; and a third wall surface that covers both side surfaces in an axial direction of the tooth. The slot insulator is formed integrally with the first wall surface of the teeth holding portion, and has a plurality of through-holes extending in the axial direction and arrayed in a radial direction.