Flat-Coil Support Structure for Compact Stator Insulation
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Solution Overview
Problem
Existing coil supports for rotary electric motors are costly and time-consuming to manufacture, and they struggle to optimize the magnetic performance-to-footprint ratio while meeting regulatory safety standards for creepage distance in limited spaces.
Innovation Solution
A coil support with an annular structure and varying columns to precisely position preformed flat coils, featuring a T-shaped groove for adhesive application and insulating sheet supports to ensure efficient potting and compliance with safety standards, optimized for a three-phase motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional spacers are used to center coils on stator teeth, then coil positioning accuracy is improved, but manufacturing time and cost increase
Solution Approach 1:
The invention removes the separate spacer component traditionally used to center coils on stator teeth. Instead, the coil support structure itself integrates the centering function through its column design, eliminating the need for additional spacers and reducing assembly steps while maintaining positioning accuracy
Solution Approach 2:
The invention combines multiple functions into the coil support structure: the columns serve both as structural support elements and as positioning features that center the coils on the stator teeth. This integration eliminates the need for separate spacer components and simplifies the overall assembly process
2Reliability
If minimum creepage distance is increased to meet safety standards, then electrical insulation performance is improved, but motor footprint increases
Solution Approach 1:
The invention applies different column widths in different locations to optimize space utilization. Columns in regions requiring greater insulation have increased width to provide the necessary creepage distance, while columns in other regions maintain minimal width to preserve space for magnetic components, thereby achieving safety standards without increasing overall motor footprint
Solution Approach 2:
The invention varies the width parameter of columns based on their specific functional requirements and positioning. By adjusting column width locally rather than uniformly, the design achieves the necessary electrical clearance for safety while minimizing the space occupied by the coil support structure
3Reliability
If column width is increased to ensure creepage distance, then electrical safety is improved, but magnetic performance-to-footprint ratio decreases
Solution Approach 1:
The invention implements local quality by assigning different column widths to different groups of columns based on their specific requirements. The first group of columns has increased width to ensure creepage distance and electrical safety, while the second group maintains minimal width to maximize space for magnetic components, thereby preserving the magnetic performance-to-footprint ratio
Solution Approach 2:
The invention changes the width parameter of columns selectively rather than uniformly. By adjusting the width of specific columns in the first group while keeping the second group at minimal width, the design achieves electrical safety requirements without unnecessarily increasing the overall footprint, thus maintaining an optimal magnetic performance-to-footprint ratio
Data Source
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AI summary
The invention relates to a coil support (10) for preformed flat coils (30) of a stator of an electric rotary motor. The coil support (10) comprises an annular supporting structure (12), and a plurality of columns (24a, 24b) extending upwardly from the supporting structure (12) and spaced apart from each other to form a corresponding plurality of coil receiving portions (22) for holding the coils in place before a potting operation. Each of the coil receiving portions (22) is configured to support a lower part of a preformed flat coil (40).