Motor
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Solution Overview
Problem
Miniaturization of motors poses a challenge in securing insulation performance due to spatial restrictions, particularly in the radial direction, where existing bus-bar and insulator structures require significant space for lead wire connections, making it difficult to reduce the motor's size and weight while maintaining insulation efficiency.
Innovation Solution
A motor design featuring a vertically stacked bus-bar, neutral-point lead wire, and insulator structure, where U, V, and W phase lead wires connect to terminals on opposite faces of the stator core, with an insulator module ensuring insulation distance between power and neutral terminal units, allowing for reduced radial thickness and miniaturization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If the stator size is reduced to achieve miniaturization and weight reduction, then the motor size and weight are reduced, but the insulation performance deteriorates due to insufficient space for insulation
Solution Approach 1:
The patent transitions from a conventional planar arrangement of bus-bars and insulators to a vertically stacked three-dimensional configuration. The insulator is positioned between the bus-bar and the stator core in the axial direction, utilizing the vertical dimension to achieve insulation without increasing radial thickness. This dimensional change allows insulation performance to be maintained while reducing the motor's overall size and weight.
2Ease of operation
If conventional bus-bar and insulator structures are used with lead wires wound around the insulator, then connections are achieved, but significant radial space is required, preventing miniaturization
Solution Approach 1:
The patent repositions the lead wire connection point from the radial direction to the axial direction. The neutral-point lead wire connects to the neutral-point terminal on the insulator in the axial direction, eliminating the need for lead wires to wrap around the insulator in the radial direction. This reduces the radial thickness significantly while maintaining ease of connection.
Solution Approach 2:
The patent integrates the neutral-point terminal directly into the insulator structure, merging the insulator and terminal functions into a single component. This eliminates the need for separate terminal structures and reduces the overall radial space requirement while maintaining connection functionality.
3Area of stationary object
If terminals are arranged on the same plane to increase space utilization, then space efficiency improves, but significant radial space is still required for insulation between terminals
Solution Approach 1:
The patent arranges the power terminals and neutral-point terminal at different vertical levels in the axial direction rather than on the same radial plane. The insulator body extends axially to provide insulation between terminals at different heights, achieving both space utilization and insulation requirements without increasing radial thickness.
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 enables miniaturization and weight reduction of the motor by reducing the outer diameter and radial thickness of the stator, while ensuring improved insulation performance and efficient lead wire connections, facilitating the use of a concentrated winding scheme with a teeth-divided core for high-speed operation.
Implementation Method 1
an insulator body for achieving insulations between the power and neutral terminal units and the stator core, and between the power and neutral terminal units
Implementation Method 2
the stator surrounds the rotor and is spaced from the rotor by a predetermined spacing... generate a rotating magnetic field, thereby inducing electrical interaction between the rotor and the stator to induce rotation of the rotor
Data Source
AI summary
Various embodiments relate to a motor in which a structure of an insulator is improved. The motor includes an insulator module coupled to a top face of a stator core. The insulator module includes: each power terminal unit connected to each of 3-phases power lead wires; a neutral terminal unit connected to a neutral point of a coil; and an insulator body for achieving insulations between the power and neutral terminal units and the stator core, and between the power and neutral terminal units, wherein the power terminal unit and the neutral terminal unit are positioned at different vertical levels.