Coil Support Segmentation for Motor Wiring and Creepage
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Solution Overview
Problem
The challenge in electric motor design is to accurately position coils and manage wiring within limited spaces, ensuring secure connections and preventing damage during potting, while meeting regulatory standards for creepage distance.
Innovation Solution
A coil support with a structured arrangement featuring coil holding portions and a connectics receiving arrangement that includes recesses for cables and through-holes for wire connections, along with a separation wall to maintain cable confinement and enhance creepage distance, facilitating accurate positioning and wiring interconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If coils are positioned accurately in a limited space, then motor performance is optimized, but wiring interconnection becomes difficult and space for cable management is insufficient
Solution Approach 1:
The coil support is segmented into distinct functional zones: a coil holding arrangement with multiple coil holding portions for precise coil positioning, and a separate connectics receiving arrangement with cable receiving portions and wire receiving portions. This segmentation allows coils to be accurately positioned while providing dedicated spaces for cable and wire management, resolving the conflict between positioning precision and wiring ease.
Solution Approach 2:
The invention utilizes vertical dimension by providing through-holes that extend from the top surface to the bottom surface of the coil support. This allows wires to pass through the coil support structure, and cables to be connected at the bottom surface, effectively using the third dimension to manage wiring connections without compromising the limited horizontal space needed for coil positioning.
2Volume of moving object
If all wires and cables are confined in a limited space, then motor size is reduced, but cables and wires are vulnerable to damage during potting operation
Solution Approach 1:
The coil support is designed with pre-formed cable receiving portions and wire receiving portions with through-holes, creating designated pathways and protected zones for cables and wires before the potting operation. This preliminary structural arrangement ensures that during the potting process, cables and wires remain confined to these protected areas, preventing damage while maintaining compact motor dimensions.
Solution Approach 2:
The coil support structure itself acts as an intermediary protective element between the cables/wires and the potting environment. The raised portions, separation walls, and recesses formed in the coil support create physical barriers and guided pathways that protect vulnerable electrical connections during the potting operation while maintaining overall motor compactness.
3Reliability
If creepage distance requirements are met, then safety standards are satisfied, but available space for component arrangement is reduced
Solution Approach 1:
The coil support incorporates localized insulating structures including raised portions and separation walls at specific critical areas where creepage distance is required. Rather than uniformly increasing spacing across the entire component area, these localized insulating features provide the necessary creepage distance only where electrical isolation is needed, thereby maintaining safety compliance while preserving maximum available space for component arrangement.
Data Source
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AI summary
The invention relates to a coil support (12) for electric motor, comprising a coil holding arrangement (14) having a plurality of coil holding portions (16) for holding a corresponding plurality of coils (40), and a connectics receiving arrangement (22) for housing interconnected cables and coil wires. The connectics receiving arrangement (22) comprises a cable receiving portion (24) having a plurality of recesses (26) for housing cables and a wire receiving portion (28) having a plurality of through-holes (30a, 30b) extending from a top surface (28a) to a bottom surface (28b) of the wire receiving portion (28). The top surface (28a) of the wire receiving portion (28) is arranged adjacent the coil holding arrangement (14) while the bottom surface (28b) of the wire receiving portion (28) is located in the connectics receiving arrangement (22) for electrical interconnection of the coils (40) with the corresponding cables. The coil support (12) further comprises a separation wall (20) arranged between the bottom surface (28b) of the wire receiving portion (28) and the coil holding arrangement (14).