Rotary Motor Insulator Recess Layout for Crossover Wire Routing
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Solution Overview
Problem
In rotary electric machines, it is challenging to route lead wires from one groove to another during coil winding, especially when a crossover wire needs to be connected between different stages, as existing techniques struggle with efficiently managing the wire routing.
Innovation Solution
A rotary electric machine design featuring an insulator with recess parts along its outer circumferential surface, allowing crossover wires to be positioned in different recess parts, facilitating easier wire routing and connection between stages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If three grooves are formed in an insulator to wind crossover wire in a three-stage structure, then the crossover wire does not overlap with crossover wire in another phase, but it is difficult to route the lead wire to the groove at the other stage
Solution Approach 1:
The patent introduces a vertical dimension by forming recesses at different heights on the insulator surface. The first recess is formed on the front surface while the second recess is formed on the rear surface, creating a three-dimensional routing path that allows lead wires to connect between stages without overlapping other phase wires. This spatial separation in the vertical dimension resolves the routing difficulty while maintaining the non-overlapping requirement.
Solution Approach 2:
The patent segments the crossover wire routing into distinct sections by providing separate recesses for different wire segments. The first recess accommodates the first crossover wire while the second recess accommodates the second crossover wire, dividing the complex routing problem into manageable segments that can be independently managed and connected.
2Reliability
If crossover wires are routed through multiple stages, then phase separation is maintained, but the winding process becomes complex
Solution Approach 1:
By utilizing the vertical dimension with recesses at different heights on the insulator, the patent simplifies the winding process while maintaining phase separation. The front surface recess and rear surface recess provide clear, separated pathways that guide the winding process through stages without requiring complex lateral maneuvers, reducing overall process complexity.
Solution Approach 2:
The insulator with its specially formed recesses acts as an intermediary structure that facilitates the crossover wire routing. The recesses serve as intermediate holding positions that simplify the transition between stages, making the winding process more manageable while ensuring proper phase separation is maintained throughout.
Data Source
AI summary
A rotary electric machine includes a first coil including a winding start and a winding end, a first crossover wire connecting to the winding start of the first coil, a second crossover wire connecting to the winding end of the first coil, and an insulator including a tubular part wound around with the first coil and an outer circumferential lateral surface coupled with the tubular part. The outer circumferential lateral surface of the insulator is formed with a plurality of recess parts in a rotation axis direction, and the first crossover wire and the second crossover wire are disposed in two recess parts located at different positions in the rotation axis direction, among the plurality of recess parts.