Motor Stator Substrate Segmentation to Reduce Manufacturing Cost
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Solution Overview
Problem
The existing configuration of motor stators with ring-shaped substrates limits the number of substrates obtainable from a substrate base material and increases manufacturing costs due to the need for enlarged substrates to accommodate power-line-connection patterns for coils with terminals arranged apart.
Innovation Solution
The motor stator design incorporates a ring-shaped stator core with separate first and second substrates, each with power supply wirings, allowing for downsized substrates even when terminals for different coils are apart, thereby increasing the number of substrates from the base material and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single ring-shaped substrate is used to connect power supply wirings to coils, then the substrate can provide a unified mounting structure, but the substrate area must be enlarged to accommodate terminals arranged apart, reducing the number of substrates obtainable from base material
Solution Approach 1:
The patent divides the single ring-shaped substrate into two separate arc-shaped substrates. Each arc-shaped substrate is assigned to connect power supply wirings to specific coils (first coil and second coil respectively). This segmentation allows each substrate to be smaller in area while still providing the necessary mounting and connection structure, thereby increasing the number of substrates that can be obtained from the base material.
2Ease of manufacture
If the substrate area is enlarged to connect power-line-connection patterns to terminals arranged apart, then all coil terminals can be connected, but the number of substrates obtainable from base material decreases and manufacturing cost increases
Solution Approach 1:
The patent segments the power supply wiring connections by assigning different arc-shaped substrates to different coils. This allows each substrate to be optimized for its specific connection requirements rather than forcing a single large substrate to accommodate all connections, thereby maintaining connectivity while improving substrate utilization efficiency.
Solution Approach 2:
The patent transitions from a single ring-shaped substrate to multiple arc-shaped substrates, changing the dimensional arrangement from one continuous structure to multiple separate structures. This dimensional change enables better spatial utilization and allows terminals arranged apart to be connected more efficiently.
3Ease of manufacture
If a ring-shaped substrate is used, then power supply wirings can be mounted on a single structure, but manufacturing cost increases due to reduced substrate utilization efficiency
Solution Approach 1:
The patent divides the ring-shaped substrate into two arc-shaped substrates, which can be independently manufactured and mounted. This segmentation improves substrate utilization efficiency by allowing each substrate to be optimized for its specific function and size, reducing waste of base material and lowering manufacturing costs.
Data Source
AI summary
A motor includes a stator, and includes a first substrate and a second substrate mounted on the stator. The stator has a stator core in a ring shape and a first coil of a first phase and a second coil of a second phase wound around the stator core. The first substrate includes a first power supply wiring to supply electric power to the first coil. The second substrate has a second power supply wiring to supply electric power to the second coil.