Cross-Shaped Stator Core for Motor Coil Space Factor
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Solution Overview
Problem
Conventional motors face challenges in improving coil space factor and productivity due to limited winding space and dual winding processes, which result in insulation issues and decreased efficiency.
Innovation Solution
A stator unit with a cross-shaped stator core and insulator groove structure allows for a single winding process to achieve dual winding, enhancing coil space factor and simplifying the winding process while addressing insulation problems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional slot structure is used, then coil winding is simple, but coil space factor is low
Solution Approach 1:
The stator core is divided into multiple teeth with distinct slot structures. Each tooth has a slot with a first width at the opening and a second width at the bottom, creating segmented winding spaces that optimize coil placement and increase the overall coil space factor.
Solution Approach 2:
Different portions of the slot have different widths to serve different functions. The wider opening facilitates coil insertion while the narrower bottom provides compact winding space, optimizing both manufacturing ease and space utilization locally within each slot.
2Adaptability or versatility
If dual winding process is used, then two individual phases can be realized, but productivity decreases
Solution Approach 1:
The patent combines multiple winding operations into a single continuous process. Coils for different phases are wound in one sequence without removing the winding tool, merging what would traditionally be separate dual winding processes into one efficient operation that maintains phase versatility.
Solution Approach 2:
The stator core structure is pre-configured with specific slot geometries and tooth arrangements that enable multiple phase windings to be completed in a single pass. This preliminary structural preparation allows the winding process to proceed efficiently without requiring multiple separate operations.
3Adaptability or versatility
If dual winding process is used, then two individual phases can be realized, but insulation problem occurs
Solution Approach 1:
The insulation structure is extracted and positioned specifically between coils of different phases. By separating the insulation function into dedicated insulating members placed at critical locations, the patent ensures reliable electrical isolation while maintaining the versatility of dual phase configuration.
Solution Approach 2:
Insulating members are introduced as intermediary elements between coils of different phases. These mediators prevent direct contact between phases, solving the insulation problem while allowing the flexible phase configuration to be maintained.
4Volume of moving object
If conventional motor design is used, then structure is simple, but motor size is large
Solution Approach 1:
The rotor is nested within the stator, with the stator core forming an outer structure that contains the rotor assembly. This nested configuration maximizes space utilization and reduces overall motor size while accommodating the more complex multi-tooth stator structure.
Solution Approach 2:
The patent optimizes the radial and axial dimensions of the stator and rotor components. By carefully designing the tooth widths, slot depths, and overall component dimensions, the patent reduces motor size in multiple dimensions while managing the increased structural complexity through precise dimensional control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution increases coil space factor by 20%, reduces motor size by 20%, and improves productivity by simplifying the winding process, maintaining performance comparable to conventional motors.
Implementation Method 1
coils having a Phase 1, a Phase 2, and a Phase 3, respectively, are wound around teeth of the stator 30, and since currents flow through the coils, a rotating magnetic field is generated between the stator 30 and the rotor 40 to rotate
Data Source
AI summary
One embodiment relates to a stator unit and a motor comprising same, the stator unit comprising: a stator core; a coil wound around the stator core; and an insulator disposed between the stator core and the coil, wherein the stator core comprises a support part, and a coil winding part disposed on both side surfaces of the support part so as to protrude therefrom, wherein the support part and the coil winding part are disposed so as to form a cross shape. Accordingly, a coil space factor may be increased by using the cross-shaped stator core.