Integrated Motor Insulating Component for Phase Isolation
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Solution Overview
Problem
Densely arranged windings in motors require extensive manual effort and increased parts count for effective insulation between phases, windings, and wiring boards, due to the need for individual insertion of insulating materials like paper.
Innovation Solution
An integrated insulating component made of resin, comprising first, second, and third insulating walls, along with a fixing unit, that provides electrical insulation between adjacent windings, windings and wiring boards, and wiring boards and stator housing, respectively, while fixing the wiring board to a predetermined position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating paper is inserted between phases of windings to improve insulation, then insulating properties are improved, but manufacturing complexity and man-hours increase
Solution Approach 1:
The patent combines multiple insulating functions into a single integrated insulating component that includes a first insulating wall for interphase insulation and a second insulating wall for winding-to-wiring board insulation. This merging eliminates the need for separate insulating papers at different locations, reducing parts count while maintaining comprehensive insulation coverage.
Solution Approach 2:
The insulating component is designed as a multi-functional element that simultaneously provides insulation between adjacent windings of different phases and insulation between windings and the wiring board. This single component performs multiple insulating tasks that previously required separate parts, simplifying the overall structure.
2Reliability
If insulating paper is inserted between windings and wiring board to ensure insulation, then insulating properties are improved, but manufacturing time and parts count increase
Solution Approach 1:
The patent integrates the second insulating wall directly into the insulating component structure, combining the function of insulating between windings and wiring board with the interphase insulation function. This eliminates the need for a separate insulating paper at the wiring board interface, reducing assembly steps and man-hours.
Solution Approach 2:
The insulating component is pre-formed as an integrated structure with both insulating walls already in place, allowing it to be installed as a single unit that simultaneously provides both types of insulation. This preliminary integration of insulating functions eliminates the need for sequential installation of multiple insulating papers during assembly.
3Reliability
If multiple separate insulating components are used to ensure comprehensive insulation, then insulating properties are improved, but device complexity and assembly time increase
Solution Approach 1:
The patent merges multiple insulating functions into a single integrated component that includes first and second insulating walls, eliminating the need for multiple separate insulating papers. This single component can be installed in one operation, significantly improving assembly efficiency while maintaining comprehensive insulation coverage.
Solution Approach 2:
The insulating component is designed as a universal element that performs multiple insulating functions simultaneously - insulating between adjacent windings and insulating between windings and the wiring board. This multi-functionality reduces the total number of components and simplifies the assembly process.
Data Source
AI summary
To provide an insulating component of a motor formed of a single component capable of ensuring insulating properties. An insulating component (2) forms a motor that comprises a stator (1), a stator housing (4) attached to the stator (1), multiple windings (14) arranged in the stator (1), and a wiring board (3) arranged at one end of the stator (1) in an axis direction of the stator (1) and used for wiring of the windings (14). The insulating component (2) comprises: a first insulating wall (21) arranged between adjacent ones of the windings (14) of different phases and electrically insulating the adjacent windings (14); and a second insulating wall (22) arranged between the windings (14) and the wiring board (3) and electrically insulating the windings (14) and the wiring board (3).