Multi-Phase Motor Coil-End Insulating Cover for Easier Assembly
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Solution Overview
Problem
Existing stator structures require complex manufacturing processes to ensure insulation properties of coil ends, necessitating uniform powder application which is challenging.
Innovation Solution
A multi-phase motor insulating structure featuring a cover part made of insulating material that holds and positions coil ends, along with a terminal holding unit to secure power terminals, eliminating the need for additional mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If powder is applied to coil ends for insulation, then insulation properties are improved, but manufacturing complexity and difficulty increase due to requirements for uniformity and accuracy in powder application
Solution Approach 1:
The patent merges the insulation function with the coil end structure itself by forming an insulating layer directly on the coil ends through a coating process. This integrates two previously separate functions (coil structure and insulation) into a single unified component, eliminating the need for separate powder application steps and reducing manufacturing complexity while maintaining insulation reliability
Solution Approach 2:
The patent replaces the mechanical powder application process with a coating process that forms an insulating layer directly on the coil ends. This substitution eliminates the need for manual or automated powder application equipment and the associated complexity of ensuring uniform powder distribution, while achieving reliable insulation through a more controllable coating process
2Reliability
If separate insulation processes are used for each coil end, then insulation reliability is improved, but manufacturing time and productivity decrease
Solution Approach 1:
The patent merges the insulation treatment of multiple coil ends into a single unified coating process. By applying the insulating coating to all coil ends simultaneously in one operation rather than treating each coil end separately, the invention maintains insulation reliability across all coil ends while significantly improving manufacturing efficiency and reducing production time
Solution Approach 2:
The coating process is designed to universally insulate all coil ends of the multi-phase coil in a single operation. This multi-functional approach allows the same process to treat multiple different coil ends simultaneously, ensuring consistent insulation reliability across all phases while maximizing manufacturing productivity through process consolidation
Data Source
AI summary
An object is to easily ensure the insulation properties of a plurality of coil ends. A multi-phase motor insulating structure is used in a multi-phase motor including a stator unit provided with a stator core and a multi-phase coil. The multi-phase motor insulating structure includes a cover part containing an insulating material. The cover part is configured to cover and hold together a plurality of coil ends of the multi-phase coil that protrudes from an end of the stator core, and defines a positional relationship between the plurality of coil ends.