Inner-Rotor Motor Stator Insulating Sleeve Positioning
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Solution Overview
Problem
In inner-rotor motors, the enameled copper wires are prone to scratching during assembly due to their proximity to the outer periphery of the stator, leading to abnormal operations and increased assembly complexity.
Innovation Solution
The stator's insulating sleeve is equipped with positioning members to which the enameled copper wires are fixed, ensuring they are spaced sufficiently away from the stator's outer periphery, preventing scratching and facilitating efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the enameled copper wire is fixed to the pin located outwardly of the outer fence plate, then the wire can be easily fixed, but the wire is very close to the outer periphery of the stator and prone to scratching during assembly
Solution Approach 1:
The patent introduces an insulating sleeve as an intermediary component between the iron core and the enameled copper wire. The wire is fixed to the insulating sleeve rather than directly to the pin on the outer fence plate. This intermediary structure provides both fixation functionality and spatial separation, pushing the wire away from the stator's outer periphery to prevent scratching during assembly while maintaining ease of fixation.
2Strength
If protrusions are added to the housing inner periphery to improve coupling strength, then the coupling area between housing and stator increases, but the enameled copper wire becomes more likely to get scratched by the housing
Solution Approach 1:
The insulating sleeve acts as a mediator that separates the enameled copper wire from the stator structure. By fixing the wire to the insulating sleeve rather than to components on the stator's outer periphery, the wire is positioned at a safe distance from the housing protrusions, eliminating the scratching hazard while allowing the protrusions to maintain their coupling function.
Solution Approach 2:
The patent moves the wire fixation point from the radial outer dimension (where it would be close to the stator periphery) to a position on the insulating sleeve that is axially displaced and radially inward. This dimensional repositioning places the wire in a safe zone away from the housing protrusions while maintaining structural integrity.
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
This solution effectively reduces the likelihood of enameled copper wire scratching during assembly, enhancing assembly efficiency and yield rate by maintaining a safe distance from the stator's periphery.
Implementation Method 1
The insulating sleeve is provided with at least one positioning member to which the enameled copper wire(s) can be fixed. Thus, it can be ensured that the enameled copper wire(s) is spaced from the outer periphery of the stator at a sufficient distance to reduce the scratching of the enameled copper wire(s) during assembly of the motor.
Implementation Method 2
The rotor includes a magnet portion mounted at the center of the stator for magnetic conduction purposes.
Data Source
AI summary
An inner-rotor motor including a housing, a stator and a rotor avoids damage to the coil unit which often occurs during assembly of the conventional inner-rotor motor. The housing has an inner periphery provided with a plurality of protrusions. The iron core has an outer periphery provided with a plurality of notches. The insulating sleeve includes a plurality of positioning members. In radial directions perpendicular to the shaft, each of the plurality of notches is spaced from a center of a shaft at a minimal distance, and each of the plurality of positioning members is spaced from the center of the shaft at a maximal distance. The maximal distance is smaller than the minimal distance.