Motor Insulating Member With Elastic Protrusions

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Solution Overview

Problem

Conventional motor assembly processes are cumbersome due to axial displacement issues of insulating members, making it difficult to automate the insertion and fixation of insulating members between coils, especially when high voltage is applied.

Innovation Solution

A motor design featuring a stator with radially extending teeth and insulators with side face covering portions, where a plate-like insulating member with elastically deformable small protrusions is used to restrict axial displacement by being inserted axially and engaged with the insulators, allowing for easier assembly and enhanced insulation through labyrinth-shaped contact faces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If projecting portions are formed on insulators to restrict axial displacement of insulating members, then axial displacement is restricted, but insertion from axial direction becomes impossible

Engineering Contradiction:

Improveaxial displacement restrictionVSAvoidinsertion ease

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The insulating member incorporates an elastically deformable small protrusion that can dynamically change its state between deformed (for insertion) and engaged (for fixation). During insertion, the protrusion is elastically deformed to pass through the insulator, and after insertion, it engages with the insulator to restrict axial displacement, thus resolving the contradiction between insertion ease and axial displacement restriction.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The small protrusion's physical state changes from deformed to engaged, altering its dimensional parameters. When deformed, the protrusion's effective size is reduced to allow insertion; when engaged, it assumes its full dimensional form to provide axial restriction. This parameter change enables both easy insertion and effective fixation.

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If insulating members are inserted through clearance between teeth, then axial displacement is restricted, but assembly becomes cumbersome

Engineering Contradiction:

Improveaxial displacement restrictionVSAvoidassembly complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The elastically deformable small protrusion allows the insulating member to be inserted axially in a simple, dynamic manner. The protrusion deforms during insertion to pass through the insulator and then engages to provide fixation, eliminating the need for complex assembly procedures through clearances between teeth.

Inventive Principle:

Principle #15Dynamics

3Stability of the object's composition

If lead wire fixation is used to secure insulating members, then axial displacement is restricted, but precise positioning is required

Engineering Contradiction:

Improveaxial displacement restrictionVSAvoidlead wire positioning precision

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The invention extracts the fixation function from the lead wire and transfers it to the small protrusion of the insulating member. The protrusion engages directly with the insulator to restrict axial displacement, eliminating the need for precise lead wire positioning and fixation while maintaining effective axial restriction.

Inventive Principle:

Principle #2Taking out (Extraction)

4Ease of manufacture

If insulating members are placed on radially inner side of teeth, then insertion is possible, but assembly work becomes cumbersome

Engineering Contradiction:

Improveinsertion possibilityVSAvoidassembly complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The elastically deformable small protrusion enables direct axial insertion of the insulating member without requiring placement on the radially inner side of teeth. The dynamic deformation and engagement of the protrusion simplifies the assembly process, eliminating cumbersome manual positioning steps.

Inventive Principle:

Principle #15Dynamics

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

Facilitates easy insertion and automation of insulating members between coils, reduces the need for precise lead wire fixation, and suppresses insulation breakdown by increasing the creepage distance, thereby simplifying the assembly process and improving electrical insulation.

Implementation Method 1

an elastically deformable small protrusion is formed at at least one of an inner side portion of the insulating member

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentEP2667489A3Motor

Publication Date: 2014.01.29 JTEKT CORP

AI summary

A motor includes a plate-like insulating member (33) that is interposed between coils located next to each other in the circumferential direction. Elastically deformable small protrusions (48), which protrude radially inward, are formed at an inner side portion (42) of the insulating member (33), the inner side portion (42) contacting inner covering portions (25) of the insulators (17). The small protrusions (48) are formed such that the insulating member (33) is allowed to be inserted between the coils from the axial direction when the small protrusions (48) are elastically deformed and the small protrusions (48) are engaged with axial end faces of the inner covering portions (25).