Motor Insulator Slit Positioning for Phase Wire Insulation Distance
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Solution Overview
Problem
In existing electric motors, the number of connecting wires along the outer circumferential surface of the insulator increases, leading to a potential decrease in insulation distance between phases and an increase in the length of the insulator in the axial direction.
Innovation Solution
A three-phase electric motor design with a cylindrical stator core and insulator featuring slits that allow connecting wires to pass through, where the deepest slit is positioned further outward in the circumferential direction than the extension of the winding body, reducing the number of connecting wires and maintaining insulation distance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the lead wire is drawn out from the slit to the outer side of the insulator without being wound around the teeth first, then the connection is simplified, but the number of connecting wires increases and the insulation distance cannot be maintained
Solution Approach 1:
The patent positions the deepest slit in the circumferential direction (radial dimension) rather than only in the axial direction. By making the deepest slit extend further in the circumferential direction beyond the extension region of the corresponding winding body, the connecting wire can be routed through this strategically positioned slit to achieve both simplified connection and maintained insulation distance.
2Length of stationary object
If the number of connecting wires is reduced, then the insulator length in axial direction can be suppressed, but the insulation distance between connecting wires in different phases may be compromised
Solution Approach 1:
The patent applies different slit depths to different positions around the insulator. The deepest slit is specifically positioned in the circumferential direction beyond the winding body extension region, while other slits may have different depths. This localized differentiation allows optimizing the routing path for reducing connecting wires while maintaining insulation distance through strategic slit positioning.
3Ease of operation
If three connecting wires are used in an electric motor including nine teeth, then each phase connection is achieved, but the insulator length increases to secure insulation distance
Solution Approach 1:
The patent performs preliminary routing of the lead wire through the deepest slit positioned in the circumferential direction before the wire needs to traverse axially. By establishing this optimal path in advance through strategic slit positioning, the connecting wire can serve multiple phases more efficiently, reducing the total number of connecting wires needed while maintaining proper insulation distances.
Data Source
AI summary
A three-phase electric motor includes a stator iron core, an insulator, and a plurality of coils. The coils are wound around teeth of the stator iron core and a winding body of the insulator. Among the plurality of coils, coils in the same phase are connected by series connection and are formed by one lead wire including connecting wires. A plurality of slits for allowing the connecting wires to pass are formed in the insulator. A deepest slit having the largest depth among the plurality of slits is provided such that at least a part of the deepest slit is located further on an outer side in a circumferential direction than an extension region obtained by virtually extending a corresponding deep groove-winding body, around which a corresponding deep groove-coil from which the connecting wires passing through the deepest slit are drawn is wound, to an outer diameter side.