Iron Core Assembly Structure for Compact Motor Insulation
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Solution Overview
Problem
In motor technology, particularly in block motors used in vehicles, the conventional insulation structure increases the volume and weight of the stator due to thicker insulating skeletons required for creepage distance, leading to higher motor resistance and reduced energy efficiency.
Innovation Solution
An iron core assembly with a mounting groove on the iron core block and an insulation protrusion on the insulating skeleton, which reduces the thickness of the insulating skeleton's end portion, allowing for sufficient creepage distance without increasing the stator's axial length, thereby minimizing motor volume and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of the insulating skeleton's end portion is increased to ensure sufficient creepage distance, then insulation reliability is improved, but the stator's axial length and volume increase
Solution Approach 1:
The insulating skeleton is segmented into two distinct parts: a thin end portion (first portion) that contacts the iron core block end surface, and a thicker main body portion (second portion) that provides creepage distance. The thin end portion reduces axial length while the groove insulation paper layered between adjacent insulating skeletons provides the necessary insulation, thereby resolving the contradiction between insulation reliability and stator volume.
Solution Approach 2:
The insulation function is shifted from the axial dimension (thickness of end portion) to the radial dimension (groove insulation paper between adjacent insulating skeletons). By placing groove insulation papers in the gaps between adjacent insulating skeletons, the creepage distance is maintained without increasing the axial thickness of the insulating skeleton's end portion.
2Reliability
If the thickness of the insulating skeleton's end portion is increased to ensure sufficient creepage distance, then insulation reliability is improved, but motor weight increases
Solution Approach 1:
The insulating skeleton is segmented into a thin end portion and a thicker main body portion. The thin end portion minimizes weight contribution while maintaining structural integrity, and the groove insulation paper provides the necessary creepage distance insulation, thereby reducing overall motor weight while preserving insulation reliability.
Solution Approach 2:
The groove insulation paper acts as an intermediary element that provides the necessary creepage distance insulation between adjacent insulating skeletons. This intermediary component enables the end portion of the insulating skeleton to be made thinner, thereby reducing motor weight while maintaining insulation reliability through the combined insulation system.
3Reliability
If the thickness of the insulating skeleton's end portion is increased to ensure sufficient creepage distance, then insulation reliability is improved, but magnet wire length and motor resistance increase
Solution Approach 1:
The insulating skeleton is segmented into a thin end portion and a thicker main body portion. The thin end portion reduces the axial length over which magnet wire must be wound, thereby reducing magnet wire length and motor resistance, while the groove insulation paper maintains the necessary creepage distance insulation.
Solution Approach 2:
The insulation function is shifted from the axial dimension to the radial dimension through groove insulation papers. This allows the end portion thickness to be minimized, reducing the coil circumference and magnet wire length required, thereby decreasing motor resistance and energy loss while maintaining insulation reliability through the radial insulation path.
Data Source
AI summary
An iron core assembly, a motor, a compressor and a vehicle are provided. The iron core assembly has an iron core body and multiple insulating skeletons. The iron core body has multiple iron core blocks. A mounting groove is provided at an edge of at least one end face of each iron core block. Each iron core block is arranged between two insulating skeletons. Out of the two insulating skeletons provided at two ends of an iron core block, an end face of at least one insulating skeleton, facing the iron core block, is provided with insulating protrusions. The insulating protrusions can wrap two sides of the iron core block. The insulating protrusions match the mounting groove.