Inner Rotor Motor Stator Radial Core Segmentation
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Solution Overview
Problem
Conventional methods for manufacturing inner rotor type motor stators require separate integration steps for A and B phase windings, which are time-consuming and prone to crossover wire damage, and involve complex winding operations.
Innovation Solution
The method involves arranging divisional core elements radially with insulating members to prevent crossover wire damage, allowing for simple series winding on the stator core without special guides, reducing winding circumference length, and forming yoke elements in a linear manner to shorten the magnetic path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate integration steps are used for A and B phase windings, then winding precision can be maintained, but manufacturing time increases and crossover wire damage risk increases
Solution Approach 1:
The patent merges the separate integration steps for A and B phase windings into a single integrated process. The stator core is divided into multiple divisional core elements that are arranged radially, allowing both A and B phase windings to be wound and integrated simultaneously, thereby reducing manufacturing time while maintaining winding precision through the radial arrangement structure.
Solution Approach 2:
The stator core is segmented into multiple divisional core elements, each with its own tooth and yoke portion. This segmentation allows for simplified winding operations on each individual element while enabling parallel processing and integration, thus reducing overall manufacturing time without compromising the precision of each winding.
2Manufacturing precision
If separate integration steps are used for A and B phase windings, then winding quality can be controlled, but device complexity increases
Solution Approach 1:
The patent combines the integration processes for A and B phase windings into a single operational framework. By arranging divisional core elements radially and winding both phases on this unified structure, the patent reduces process complexity while maintaining winding quality through consistent geometric relationships and standardized winding procedures.
Solution Approach 2:
The radial arrangement of divisional core elements creates a universal structure that can accommodate both A and B phase windings simultaneously. This multi-functional design allows a single integration process to handle both phases, reducing the need for separate specialized procedures and thereby simplifying the overall device complexity.
3Manufacturing precision
If complex winding operations with special guides are used, then winding precision can be maintained, but ease of manufacture decreases
Solution Approach 1:
The stator core is divided into multiple divisional core elements arranged radially, with each element having a simplified tooth and yoke structure. This segmentation allows windings to be performed on individual elements without requiring complex guides, as each element presents a simple, standardized geometry that is easy to wind while maintaining overall precision through the radial arrangement.
4Reliability
If divisional core elements are arranged radially with insulating members, then crossover wire damage is prevented, but device complexity increases
Solution Approach 1:
Insulating members are introduced as intermediary elements between the divisional core elements in the radial arrangement. These insulating members serve as protective barriers that prevent crossover wire damage by providing electrical insulation and physical separation, thereby enhancing reliability while adding only minimal structural complexity.
Data Source
AI summary
A stator for an inner rotor type motor includes a stator core 1, insulating members 10 and winding wire 3, 4. The stator core 1 includes: four divisional core elements 6 each integrally formed by setting up one tooth 2 to one yoke portion 8; and four divisional yoke elements 7. A rotor opening 11 is formed on top portions of the teeth 2 by arranging the divisional core elements 6 so that the teeth 2 are radially disposed. Four slots 9 are formed by respectively arranging the divisional yoke elements 7 between the yoke portions 8 of the adjacent divisional core elements 6. The winding wire 3, 4 is wound on the teeth 2. An inner surface of each yoke portion 8 is substantially perpendicular to the central axis of the corresponding tooth 2 while the insulating member 10 is provided on side surfaces of each tooth 2.