Electric Motor Stator Core Thinning via Insulator Segmentation
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Solution Overview
Problem
Conventional inner rotor type electronic motors face challenges in increasing rotor diameter while maintaining the outside diameter of the stator unchanged, leading to issues with stator core thinning and accurate coil winding positioning due to reduced stator core rigidity.
Innovation Solution
The stator core is thinned by creating cut-away parts at predetermined intervals on the insulator flanges, allowing for precise positioning during coil winding and enabling increased rotor diameter without altering the stator's outside diameter, with the insulator divided into segments for cost-effective manufacturing and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the rotor diameter is increased to increase power output, then the power output is improved, but the stator outside diameter must be increased accordingly
Solution Approach 1:
The patent shifts the design constraint from the radial dimension (stator outside diameter) to the axial dimension (stator core thickness). By reducing the stator core thickness in the axial direction, the rotor diameter can be increased while maintaining the same stator outside diameter, thus resolving the contradiction between power output and stator size.
2Length of stationary object
If the stator core thickness is reduced to increase rotor diameter, then the rotor diameter is improved, but the positioning accuracy during coil winding deteriorates
Solution Approach 1:
The insulator is divided into multiple segments that can be assembled around the stator core. These segmented insulators provide positioning protrusions that engage with corresponding positioning grooves on the stator core, enabling accurate positioning during coil winding even when the stator core is thin.
Solution Approach 2:
The insulator acts as an intermediary component between the stator core and the coil winding process. By providing positioning protrusions on the insulator, the system achieves accurate positioning without relying on the stator core's own geometric features, thus resolving the positioning accuracy issue.
3Length of stationary object
If the stator core is thinned to increase rotor diameter, then the rotor diameter is improved, but the stator core rigidity deteriorates
Solution Approach 1:
The patent uses a composite structure combining the stator core with the insulator material. The insulator provides additional structural support and rigidity to the thinned stator core, compensating for the reduced stiffness while allowing the rotor diameter to be increased.
Data Source
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AI summary
There is provided an electronic motor in which a stator core is thinned to obtain an increased diameter of a rotor is to produce a high power output, and a stator can be positioned with high accuracy at the time when a coil is wound on the stator. The outside peripheral surface of a yoke part 31 is substantially the same as the outside peripheral surface of a flange 42 of an insulator 4, and in a part of the flange 42, a cut-away part 43 is provided to expose a part of the end face of a stator core 30.