Motor
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Solution Overview
Problem
Miniaturization of motors poses a challenge in securing insulation performance due to spatial restrictions, particularly in the radial direction, where existing bus-bar and insulator structures require significant space for lead wire connections, making it difficult to reduce the motor's size and weight while maintaining insulation efficiency.
Innovation Solution
A motor design featuring a vertically stacked bus-bar, neutral-point lead wire, and insulator structure, where U, V, and W phase lead wires connect to terminals on opposite faces of the stator core, with an insulator module ensuring insulation between these components, allowing for reduced radial thickness and miniaturization by utilizing a teeth-divided core coupled axially to the stator core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the motor size is reduced for miniaturization, then weight and spatial footprint are reduced, but insulation performance deteriorates due to insufficient space for insulation between components
Solution Approach 1:
The patent transitions from a planar arrangement of bus-bars and terminals to a three-dimensional vertically stacked configuration. The insulator body extends in the vertical direction with terminal units positioned at different heights, allowing insulation to be achieved through vertical separation rather than requiring large radial or axial horizontal distances. This dimensional change enables miniaturization while maintaining insulation performance.
Solution Approach 2:
The patent implements a nested structure where terminal units are positioned within or alongside the insulator body in a compact vertical arrangement. The bus-bars and terminals are integrated into the insulator structure with multiple components stacked within the limited vertical space, creating a nested configuration that maximizes space utilization while ensuring insulation.
2Ease of operation
If conventional bus-bar and insulator structures are used with lead wires wound around the insulator, then connection is achieved, but significant radial space is required
Solution Approach 1:
The patent extracts the lead wire winding function from the insulator structure. Instead of winding lead wires around the insulator, the design uses direct terminal units with lead wires connected at different vertical levels. This eliminates the need for radial space required for winding operations while maintaining connection functionality.
Solution Approach 2:
The patent moves the connection function from a radial arrangement (winding around the insulator) to a vertical arrangement (stacked terminal units). Lead wires are connected at different vertical levels rather than being wound radially, transferring the connection geometry from the radial dimension to the vertical dimension and reducing radial thickness requirements.
3Area of stationary object
If terminals are arranged on the same plane to increase space utilization, then area efficiency improves, but radial space requirement increases for insulation
Solution Approach 1:
The patent resolves the contradiction by moving terminal arrangements from a two-dimensional planar configuration to a three-dimensional vertical stacking configuration. Terminal units are positioned at different vertical levels within the insulator body, allowing compact planar footprint while achieving insulation through vertical separation rather than radial distance.
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 design achieves miniaturization and weight reduction of the motor while ensuring improved insulation performance and efficient lead wire connections, overcoming spatial constraints and enhancing the motor's performance.
Implementation Method 1
an insulator body for achieving insulations between the power and neutral terminal units and the stator core, and between the power and neutral terminal units
Implementation Method 2
the stator surrounds the rotor and is spaced from the rotor by a predetermined spacing... generate a rotating magnetic field, thereby inducing electrical interaction between the rotor and the stator to induce rotation of the rotor
Data Source
AI summary
Various embodiments relate to a motor in which a structure of an insulator is improved. The motor includes an insulator module coupled to a top face of a stator core. The insulator module includes: each power terminal unit connected to each of 3-phases power lead wires; a neutral terminal unit connected to a neutral point of a coil; and an insulator body for achieving insulations between the power and neutral terminal units and the stator core, and between the power and neutral terminal units, wherein the power terminal unit and the neutral terminal unit are positioned at different vertical levels.