Motor Coil Terminal Structure to Prevent End Twisting
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Solution Overview
Problem
The existing motor designs face issues with coil twisting during the fusion process, leading to increased resistance and potential motor failure, which complicates the manufacturing process and reduces production efficiency.
Innovation Solution
The motor design incorporates a protruding portion on the insulator that creates a height difference for the coil ends, preventing twisting and enhancing the coupling force between the coil and terminal, while simplifying the manufacturing process and reducing the motor's overall size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If both ends of the coil are fused together in a single coil coupling portion, then the structure is simplified, but the coil may twist within the coupling portion causing increased resistance or breakage
Solution Approach 1:
The coil coupling portion is divided into two separate coupling regions: a first coil coupling portion for receiving one end of the coil and a second coil coupling portion for receiving the other end. This segmentation prevents the coil ends from interfering with each other and twisting, while maintaining structural simplicity through the integrated terminal body.
Solution Approach 2:
Different regions of the terminal are designed with different coupling characteristics. The first and second coil coupling portions are positioned at different locations and orientations, providing localized coupling zones that accommodate the spatial arrangement of coil ends without causing twisting.
2Ease of manufacture
If the coil ends are coupled to the terminal without support structures, then the manufacturing process is simpler, but the coil may twist during fusing
Solution Approach 1:
The first and second support portions are pre-formed as integral parts of the terminal structure before coil installation. These support portions preliminarily position the coil ends in correct spatial relationships, guiding proper alignment during the subsequent fusing process and preventing twisting.
Solution Approach 2:
The support portions act as intermediary structures between the coil ends and the coil coupling portions. They provide a stable reference framework that mediates the positioning of coil ends, ensuring accurate alignment and preventing twisting during the fusing operation.
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 effectively prevents coil twisting, maintains a strong coupling force, and improves production efficiency by simplifying the manufacturing process and reducing the motor's size compared to conventional designs.
Implementation Method 1
a rotational force is generated by electromagnetic interaction of the coil and the magnet
Data Source
AI summary
A motor comprises: a stator core; an insulator coupled to the stator core; a coil wound around an outer surface of the insulator; and a terminal coupled to the insulator, wherein the terminal includes a coil coupling portion to which both ends of the coil are coupled, and the insulator includes a protruding portion which protrudes further upward compared to other regions and supports any one of both ends of the coil.