Motor Stator Wire Routing Recesses for Easier Substrate Assembly
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Solution Overview
Problem
The routing of conducting wires from a coil to a substrate in a motor is hindered by interference with insulator walls, complicating the assembly process.
Innovation Solution
A motor design featuring a stator with recessed areas on the insulator and substrate to accommodate the conducting wire ends, allowing for improved alignment and assembly without interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conducting wire is routed from the coil to the substrate, then electrical connection is achieved, but the insulator wall interferes with the routing making assembly difficult
Solution Approach 1:
The insulator wall is segmented by forming recess parts that create separate routing paths for different conducting wires. This segmentation allows each wire to be routed independently through designated channels, avoiding interference between multiple wires and the insulator wall, thereby improving assemblability while maintaining reliable electrical connections.
Solution Approach 2:
The recess parts in the insulator wall act as intermediary structures that facilitate the routing of conducting wires. These recesses provide dedicated pathways that mediate between the coil and substrate, allowing wires to pass through without direct contact with the insulator wall, thus solving the interference problem while ensuring proper electrical connection.
2Area of stationary object
If multiple conducting wires are routed close together, then space is efficiently used, but the load on the wires increases due to interference with the insulator wall
Solution Approach 1:
The insulator wall is divided into multiple recess parts, each accommodating a specific conducting wire. This segmentation allows wires to be positioned close together in the circumferential direction while maintaining separate, interference-free pathways, thus achieving efficient space utilization without increasing the load on individual wires.
Solution Approach 2:
Different regions of the insulator wall are given different local qualities through the formation of recess parts at specific positions. Each recess is strategically located to accommodate wires drawn at different positions, creating localized pathways that reduce interference and load on each wire while maintaining overall compactness.
3Adaptability or versatility
If the conducting wire is drawn at different positions from the coil, then routing flexibility is improved, but alignment with the substrate becomes more difficult
Solution Approach 1:
The recess parts are pre-formed in the insulator wall at specific positions that correspond to the drawing positions of the conducting wires from the coil. This preliminary action ensures that when wires are drawn at different positions, they automatically align with their designated recesses, which in turn align with the corresponding connection terminals on the substrate, thus maintaining manufacturing precision while allowing routing flexibility.
Solution Approach 2:
Each recess part is positioned at a specific location on the insulator wall, creating localized alignment features. This local quality approach ensures that wires drawn at different positions have dedicated alignment pathways, making it easier to route them flexibly while maintaining precise alignment with the substrate connection points.
Data Source
AI summary
In a motor of an embodiment, an insulator includes a wall part having two recess parts (an insulator-side first recess part and an insulator-side second recess part) opposed to two drawing positions of a conducting wire drawn out from a coil in a radial direction. One of the two drawing positions is located at an outer peripheral portion of the coil, and the other is located at an inside of the outer peripheral portion. A substrate includes a substrate-side first recess part and a substrate-side second recess part recessed at an inside in the radial direction from an outer peripheral end and adjacent to each other in a circumferential direction. The substrate-side first recess part is opposed to the insulator-side first recess part, and the substrate-side second recess part is opposed to the insulator-side second recess part.