Motor Stator Insulating Member Design for Coil Capacity
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Solution Overview
Problem
Existing motor designs face insulation performance deterioration due to separable insulating films and require custom manufacturing of separate insulating members, which reduces coil accommodation capacity.
Innovation Solution
A motor design featuring insulating films fixed by teeth and insulating members covering the stator's upper and lower portions, with protrusion parts and film fixing parts to securely position and fix the insulating films, allowing for improved insulation and increased coil accommodation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate insulating members are inserted into slots to insulate teeth and coil, then insulation performance is improved, but device complexity increases and manufacturing becomes more difficult
Solution Approach 1:
The patent combines multiple insulating functions into a single integrated insulating member that simultaneously provides slot insulation, tooth insulation, and coil insulation. This unified structure eliminates the need for separate insulating components, reducing assembly complexity while maintaining comprehensive insulation performance.
Solution Approach 2:
The insulating member is designed with multi-functional capabilities: it serves as the slot insulator, provides tooth insulation through integrated structures, and offers coil insulation. This single component performs multiple insulating functions that previously required separate parts, simplifying the overall structure.
2Reliability
If insulating films are inserted into slots to insulate coil from teeth, then insulation is provided, but insulating films separate or change position during coil winding causing insulation performance deterioration
Solution Approach 1:
The insulating member is pre-formed with integrated structures including protrusions that fit into corresponding grooves on the teeth. This preliminary configuration ensures that when the coil is wound, the insulating member remains firmly in position without shifting or separating, as the interlocking structures prevent movement during the winding process.
Solution Approach 2:
The insulating member acts as an intermediary between the teeth and the coil, with its integrated design including protrusions that engage with the teeth. This intermediary structure provides stable positioning and maintains insulation performance throughout the coil winding process by preventing film separation or displacement.
3Reliability
If separate insulating members are used to insulate slots, then insulation is achieved, but coil accommodation capacity is reduced due to thickness of insulating members
Solution Approach 1:
The insulating member employs local thickness variation with thinner regions in areas where coil accommodation is critical and thicker regions where insulation requirements are higher. This localized quality optimization provides adequate insulation performance while minimizing the volume occupied by insulating material, thereby maximizing coil accommodation capacity.
Solution Approach 2:
The insulating member utilizes materials or structures with optimized thickness parameters that provide sufficient insulation performance while reducing overall volume. By carefully controlling and varying the thickness parameter in different regions, the design achieves the necessary insulation effect without excessively reducing the space available for coil winding.
4Reliability
If insulating films are used to insulate coil from teeth, then insulation is provided, but insulating films require custom manufacturing for different slot lengths increasing manufacturing complexity
Solution Approach 1:
The insulating member is designed as a universal component that can accommodate different slot lengths through its integrated structure. The standardized design with proportional scaling allows a single manufacturing process to produce insulating members suitable for various slot configurations, eliminating the need for custom manufacturing for each specific slot length.
Solution Approach 2:
The insulating member design allows for parameter scaling where the overall dimensions are adjusted according to slot length requirements while maintaining the same structural features and manufacturing process. This parametric design approach enables production of insulating members for different applications using standardized manufacturing methods rather than custom processes.
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
Enhances insulation performance and coil accommodation capacity while preventing film separation and reducing the need for custom insulating member manufacturing.
Implementation Method 1
insulating members covering upper and lower portions of the stator, respectively
Implementation Method 2
the plurality of insulating films are fixed by the plurality of teeth and the insulating members
Implementation Method 3
rotates the rotor by electromagnetic force between the stator and the rotor
Data Source
AI summary
A motor is provided. The motor includes: a rotor; a stator inside which the rotor is rotatably disposed and including a plurality of teeth protruding toward the rotor; a plurality of insulating films disposed in respective slots formed between the plurality of teeth to insulate a coil wound around the plurality of teeth from the respective teeth; and insulating members covering upper and lower portions of the stator, respectively, wherein the plurality of insulating films are fixed by the plurality of teeth and the insulating members.