Motor Stator Core Welding Protection via Terminal Block
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Solution Overview
Problem
Conventional motors with exposed welded portions for fixing stator cores are prone to damage from contact with objects or people, leading to potential noise and vibration issues.
Innovation Solution
The motor design includes two stator assemblies with welded stator cores covered by terminal blocks on the outer side, providing a predetermined space to protect the welded portions and ensuring secure fixation without exposing them to contact risks, while also allowing for relief parts in the stator cores or terminal blocks to accommodate the welded areas and maintain press-in margins for coil wire bindings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welded portions are provided at edges of opening part or in vicinity of opening part to fix stator cores to case, then fixation strength is improved, but welded portions become exposed and vulnerable to damage from contact with persons or objects
Solution Approach 1:
The terminal block serves as an intermediary protective element that covers the welded portion. The terminal block is positioned to extend in the radial direction and cover the welded area, preventing direct contact between the welded portion and external objects or persons, thereby protecting the fixation strength while eliminating vulnerability to damage.
2Reliability
If terminal block covers welded portion on outer side in radial direction, then protection from contact is improved, but space for accommodating welded portion must be created
Solution Approach 1:
The relief part is formed by creating a recessed space in the radial dimension, allowing the terminal block to cover the welded portion without increasing the overall radial dimensions of the motor. This dimensional approach accommodates the welded portion within the existing structure while maintaining protection.
3Device complexity
If relief part is provided in stator cores to accommodate welded portion, then space for welded portion is created, but press-in margin for coil wire binding may be reduced
Solution Approach 1:
The relief part is localized to specific regions of the stator core where space accommodation is needed, while maintaining the full thickness and press-in margin in other critical areas. This localized approach creates necessary space for the welded portion without compromising the structural integrity and electrical connection strength in other areas.
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
This design effectively prevents damage to the welded portions from contact and ensures robust fixation of stator cores, reducing the risk of noise and vibration while maintaining efficient electrical connections.
Implementation Method 1
The stator core structuring one of the two stator assemblies which is located on a side of the other stator assembly and the stator core structuring the other stator assembly which is located on a side of the one stator assembly are welded together and fixed to each other
Data Source
AI summary
A motor may include a rotor and a stator. The stator may include first and second stator assemblies. Each stator assembly may include a coil wound around a tube-shaped body part of a bobbin comprising a terminal block; and first and second stator cores disposed on opposite sides of the coil. The first stator cores of the first and second stator assemblies are welded together at outer peripheries of the first stator cores of the first and second stator assemblies. The welded portion may be covered by the terminal block of one of the first stator assembly or the second stator assembly on an outer side in the radial direction with a predetermined space between the welded portion and the terminal block.