Insulator Slope for Variable Coil Diameter Winding
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Solution Overview
Problem
Conventional motor designs require frequent mold changes and increased costs due to variations in coil diameter, leading to inconsistent motor performance and inefficient coil winding processes.
Innovation Solution
A motor configuration where the outer circumferential surface of the insulator is inclined at a specific angle, allowing for regular winding of coils with different diameters without altering the insulator shape, thereby reducing manufacturing costs and improving coil space factor and motor efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the width of the holding groove or the step/slope dimensions are changed to accommodate different coil diameters, then coils with different diameters can be wound, but the mold must be reformed each time, increasing manufacturing costs
Solution Approach 1:
The patent applies parameter changes by modifying the inclination angle of the outer circumferential surface of the insulator. Instead of changing the mold structure for different coil diameters, the design uses a fixed mold that produces an insulator with a specific inclination angle (α), allowing the same mold to accommodate various coil diameters through the geometric property of the inclined surface.
Solution Approach 2:
The insulator design achieves universality by creating a single mold structure that can produce insulators suitable for multiple coil diameters. The inclined outer circumferential surface serves multiple functions: it guides the coil winding process, accommodates different coil sizes, and maintains proper coil positioning, eliminating the need for multiple specialized molds.
2Ease of manufacture
If conventional insulator designs are used, then manufacturing is straightforward, but coil winding becomes irregular and prone to failure when coil diameters vary
Solution Approach 1:
The patent introduces a specific inclination angle parameter (α) for the outer circumferential surface of the insulator. This parameter change transforms the winding process by providing a consistent geometric reference that guides the coil layers, ensuring regular winding patterns and reducing winding failures while maintaining manufacturing simplicity.
Solution Approach 2:
The inclined outer circumferential surface introduces a curved geometric feature that facilitates smooth coil placement. The continuous inclined surface guides the coil wire along a predictable path, ensuring consistent layer formation and improving winding reliability compared to flat or stepped surfaces.
3Reliability
If the insulator shape is modified to accommodate different coil diameters, then winding reliability improves, but manufacturing costs increase due to mold changes
Solution Approach 1:
The patent resolves this contradiction by changing the geometric parameter of the insulator (inclination angle α) rather than the overall insulator shape or structure. This parameter modification provides winding reliability for different coil diameters while maintaining the same basic insulator form, thus avoiding costly mold reforms.
4Productivity
If the coil space factor is increased to improve motor efficiency, then more coils can be disposed in the stator, but the winding process becomes more complex and error-prone
Solution Approach 1:
The inclined outer circumferential surface provides a curved guiding surface that facilitates the placement of multiple coil layers. The continuous inclination angle creates natural spacing and alignment for successive layers, making the complex multilayer winding process more stable and reliable while maximizing coil density in the stator.
Data Source
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AI summary
An insulator 5 includes a part 50 to be wound with a coil 7 of a wiring wire with a circular cross section; a first flange 51; and a second flange 52. The first flange 51 is formed at the side of the part 50 closer to a core segment 41. The second flange 52 is formed at the side closer to a distal end of a tooth 42. The part 50 to be wound with the coil has a slope 50a continuous with the first flange 51 and inclined so that a height from an upper surface 42a of the tooth 42 increases from the first flange 51 toward the second flange 52. Expression 0 < (-6.8 D + b) ≤ α <30 is satisfied, where b is a constant and 8.3 ≤ b ≤ 11.6 is satisfied, D (mm) is a diameter of the coil, and α (°) is an angle of the slope inclined from the upper surface 42a of the tooth 42 as a reference surface.