Stator Terminal Hook Structure for Automated Motor Coil Winding
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Solution Overview
Problem
The existing motor manufacturing process is hindered by the cumbersome manual arrangement of coil ends with terminals, leading to automation challenges and quality degradation in the fusing process.
Innovation Solution
A motor design featuring a stator with a terminal extension having a pin and hook structure, where the coil is wound around body portions and passes through the hook for electrical connection, allowing for automated hooking and improved positional alignment, with additional features like bent pieces and coupling portions to secure the terminal in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual arrangement of coil ends with terminals is performed, then positioning can be adjusted, but automation is hindered and manufacturing efficiency decreases
Solution Approach 1:
The terminal is pre-formed with an extension and hook structure before coil winding. The extension protrudes in the circumferential direction and the hook is positioned to receive the coil end automatically during the winding process, eliminating the need for manual arrangement after coil completion.
Solution Approach 2:
The hook structure on the terminal automatically receives and secures the coil end through its own geometry during the winding process. The coil end is guided into the hook by the extension structure itself, making the terminal self-sufficient for the hooking operation without requiring additional manual intervention or complex positioning mechanisms.
2Productivity
If manual positioning of coil ends with terminals is performed, then alignment can be achieved, but manufacturing time increases and productivity decreases
Solution Approach 1:
The extension and hook are pre-formed on the terminal at precise positions before coil winding. The extension protrudes in the circumferential direction with the hook positioned to automatically receive the coil end, ensuring precise alignment is built into the terminal structure itself rather than requiring manual adjustment during assembly.
Solution Approach 2:
The extension acts as an intermediary structure that guides the coil end into the hook during winding. The extension protrudes in the circumferential direction and provides a path for the coil end to follow, ensuring accurate positioning and alignment between the coil and terminal without requiring manual intervention.
3Reliability
If simple terminal structure is used, then manufacturing is easier, but coil may detach during rotation
Solution Approach 1:
The terminal is segmented into distinct functional parts: the main terminal body, the extension protruding in the circumferential direction, and the hook structure. This segmentation allows each part to perform its specific function - the extension guides the coil end and the hook secures it - while maintaining overall structural simplicity and ease of manufacturing.
Solution Approach 2:
The hook structure utilizes a curved or bent geometry to receive and secure the coil end. The curved shape of the hook provides mechanical retention of the coil end through its geometry, preventing detachment during rotation while adding minimal complexity to the terminal structure.
Data Source
AI summary
The present invention provides a motor comprising: a shaft; a rotor coupled to the shaft; a stator arranged on the outer side of the rotor; and a terminal arranged on the stator. The stator comprises: a stator core; an insulator coupled to the stator core; and a coil wound on the insulator, wherein the insulator comprises a body on which the coil is wound, and a connector connected to the body. The terminal comprises: an extension arranged in the circumferential direction of the insulator, a pin portion at an end of the extension, and a hook portion at the opposite end of the extension. The coil comprises one continuous wire. The body comprises a first body and a second body, the coil being wound on the first body, passing through the hook portion, and wound on the second body. The hook portion is electrically connected to a portion of the coil, wherein the portion passes through the hook portion.