Rotary Motor Coil Support for Precise Flat-Coil Positioning
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Solution Overview
Problem
The existing methods for coil positioning in electric motors are time-consuming and costly, and they struggle to achieve the required minimum creepage distance in limited spaces while maintaining magnetic performance, which is essential for safety and efficiency.
Innovation Solution
A coil support with an annular structure and spaced columns to hold preformed flat coils, allowing for precise positioning and gluing before potting, while optimizing the magnetic performance to footprint ratio and adhering to safety standards through varying column widths and grooves for adhesive application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spacers are used to position coils on stator teeth, then coil positioning accuracy is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent integrates the coil positioning function directly into the stator tooth structure by forming positioning protrusions on the stator teeth that engage with corresponding grooves in the coil supports. This merging of the positioning function into the existing structural components eliminates the need for separate spacer elements, thereby maintaining precise coil positioning while reducing assembly steps and manufacturing cost.
Solution Approach 2:
The invention extracts the positioning function from separate spacer components and relocates it to the stator tooth structure itself through integrated positioning protrusions. This extraction eliminates the need for additional spacer parts and their associated assembly operations, resolving the contradiction between positioning accuracy and assembly efficiency.
2Area of stationary object
If coil spacing is reduced to minimize motor footprint, then device size is reduced, but creepage distance requirements for safety may not be met
Solution Approach 1:
The patent applies different structural characteristics to different regions of the coil support system. The coil supports feature localized insulating structures and positioning geometries that ensure adequate creepage distances between adjacent coils in critical areas, while allowing tighter spacing in regions where magnetic performance requirements dominate. This local differentiation enables simultaneous optimization of both compactness and safety compliance.
Solution Approach 2:
The coil supports act as intermediary structures between the stator teeth and the coils, providing isolated mounting positions that maintain required creepage distances. These supports serve as mediating elements that enable close coil spacing for compact motor design while ensuring that electrical clearance requirements are met through their insulating properties and geometric configuration.
3Stability of the object's composition
If traditional coil positioning methods are used, then coil stability is ensured, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the coil support structure with the positioning function by integrating positioning protrusions directly onto the stator teeth. This merging eliminates the need for separate positioning devices and simplifies the overall system while maintaining coil stability through the direct mechanical engagement between the positioning protrusions and the coil support grooves.
Solution Approach 2:
The stator teeth provide their own positioning functionality through the integrated positioning protrusions, eliminating the need for external positioning mechanisms. The structure serves itself by incorporating the positioning function directly into the stator components, thereby reducing overall system complexity while ensuring stable coil placement.
Data Source
AI summary
A coil support for preformed flat coils of a stator of an electric rotary motor includes an annular supporting structure and a plurality of columns extending upwardly from the supporting structure. The columns are spaced apart from each other to form a corresponding plurality of coil receiving portions configured to hold the preformed flat coils in place before a potting operation. Each of the coil receiving portions is configured to support a lower part of one of the preformed flat coils.