Motor Stator Insulator Structure for Uniform Coil End Positioning
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Solution Overview
Problem
The inconsistent positioning of finishing ends of coils due to winding process tension or loosening poses a challenge in motor manufacturing automation and affects the quality of fusing in electronic power steering systems.
Innovation Solution
The use of a stator with first and second insulators, where the coil is wound around the insulators with guides and slots, allowing the finishing ends to be precisely positioned and fixed in grooves, ensuring uniform alignment and fusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional coil winding process is used, then coil winding is simple, but finishing ends positions are not uniform
Solution Approach 1:
The insulator is designed with pre-formed guides and slots before coil winding. The guides extend from the insulator body to indicate where finishing ends should be placed, and slots are pre-positioned to receive and fix the finishing ends. This preliminary structuring ensures uniform finishing ends positioning without requiring complex post-winding adjustments.
Solution Approach 2:
The insulator acts as an intermediary component between the coil winding process and the final assembly. It provides physical guides and slots that mediate the positioning of finishing ends, translating the winding process output into uniformly positioned terminals ready for connection.
2Reliability
If finishing ends positions are not uniform, then manufacturing can proceed, but fusing quality degrades
Solution Approach 1:
The patent replaces manual positioning and adjustment mechanisms with a mechanically predetermined insulator structure. The guides and slots provide automatic mechanical guidance that ensures uniform finishing ends positioning, enabling automation while maintaining high fusing quality.
Solution Approach 2:
The insulator structure changes the positional parameters of finishing ends by providing fixed geometric references (guides and slots). This transforms the variable positioning problem into a fixed-parameter system where finishing ends naturally align to predetermined positions, improving both quality and manufacturability.
3Manufacturing precision
If guides and slots are added to insulators, then finishing ends positioning is precise, but insulator complexity increases
Solution Approach 1:
The guides and slots are merged into a single integrated insulator component rather than being separate parts. The insulator body incorporates both the guiding function (through extended guides) and the fixing function (through slots) in one piece, reducing overall system complexity while achieving precise positioning.
Solution Approach 2:
The insulator is designed as a multi-functional component that simultaneously provides electrical insulation, mechanical guidance (via guides), and positional fixation (via slots). This universal design achieves precise positioning without requiring additional specialized components.
Data Source
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AI summary
The present invention may provide a motor including a housing, a stator disposed in the housing, a rotor disposed inside the stator, and a shaft coupled to the rotor, wherein the stator includes a stator core, a first insulator disposed on the stator core, and a coil disposed on the first insulator, the first insulator includes a body on which the coil is disposed, a guide extending from one side of the body and including an opening, and a holder extending from one portion of the guide and including a groove, and one portion of the coil is disposed in the opening of the guide and the groove of the holder.