Motor Stator Wire-Clamping Structure for Precise Lead-Out Alignment
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Solution Overview
Problem
The manual alignment and connection of lead-out wires in conventional motor stators is challenging, requiring skilled labor and time-consuming, and cannot be automated, leading to inefficiencies and potential issues like uneven winding or loosening of wires.
Innovation Solution
A motor stator structure with wire clamping units on insulated supports that include slide guiding and retaining sections, allowing lead-out wires to be quickly and precisely positioned for automated connection to a circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual alignment and connection of lead-out wires is used, then flexibility and adaptability are maintained, but productivity is low and manufacturing precision is difficult to ensure
Solution Approach 1:
The wire clamping member is divided into distinct functional sections: a slide guiding section for positioning and a retaining section for fixation. This segmentation allows each section to perform its specific function efficiently, enabling automated manipulation while maintaining structural clarity
Solution Approach 2:
The wire clamping member acts as an intermediary device between the lead-out wire and the automated production line. It provides a standardized interface that enables automated grippers to manipulate the wires, bridging the gap between manual flexibility and automated efficiency
2Manufacturing precision
If manual wire connection is performed, then adaptability to different configurations is possible, but manufacturing precision and alignment accuracy are inconsistent
Solution Approach 1:
The wire clamping member features localized functional zones with different geometric properties. The slide guiding section has smooth surfaces for precise wire insertion, while the retaining section has engagement features for secure fixation. This local differentiation ensures high precision wire positioning without requiring complex overall structure
Solution Approach 2:
The slide guiding section预先 (in advance) guides the lead-out wire into the correct position before the retaining section engages it. This preliminary positioning action ensures that the wire is already aligned properly before final fixation, guaranteeing manufacturing precision
3Productivity
If complex wire routing through multiple grooves and segments is used, then connection reliability can be achieved, but operation time increases and productivity decreases
Solution Approach 1:
The invention extracts the essential functions of wire routing (guiding and securing) from the complex multi-groove and multi-segment system into a single integrated wire clamping member. This extraction maintains the necessary reliability functions while dramatically simplifying the operation sequence and reducing time consumption
Solution Approach 2:
The slide guiding section and retaining section are merged into a single wire clamping member that performs both positioning and fixation functions simultaneously. This merging eliminates the need for separate routing through multiple grooves and segments, reducing operation steps while maintaining connection reliability
Data Source
AI summary
A motor stator structure includes a plural set of silicon steel laminations, a plurality of insulated supports including at least one wire clamping unit, and a plurality of windings. Each set of the silicon steel laminations is clamped on one of the insulated supports. The wire clamping unit includes at least one wire clamping member, which includes a slide guiding section and a retaining section. The windings are wound around the sets of silicon steel laminations and the insulated supports, and respectively include at least one lead-out wire extended to an outer side of the insulated supports. The outward extended lead-out wire can be moved from the slide guiding section into the retaining section and be firmly held thereto, so as to ensure the lead-out wire is quickly and precisely located at a predetermined position while being pulled tightly.