Segment Conductor Motor Axial Lead Placement
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Solution Overview
Problem
Existing motor designs with segment conductor (SC) coils face challenges in reducing cogging torque and physical size, particularly in applications like EPS motors, where the SC coil configuration increases the motor's diameter due to welding requirements, and the integration of control circuit units further complicates miniaturization.
Innovation Solution
A brushless motor design featuring a stator with U-shaped segments inserted into slots, where the segments are interconnected to form an SC coil, and the motor case is structured with a tubular portion and covers to accommodate a rotor and stator, with leads extending parallel to the axis for power supply, allowing for reduced size through optimized terminal placement and housing recesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding portions are separated radially to prevent short-circuiting, then reliability is improved, but the stator diameter increases
Solution Approach 1:
The patent transitions the separation direction from radial to axial dimension. By extending leads axially and positioning receiving terminals on the axial end surface of the stator core, the design eliminates the need for radial separation of welding portions, thereby preventing short-circuiting without increasing stator diameter.
2Adaptability or versatility
If control circuit unit is mounted on outer circumferential surface, then integration is improved, but radial size increases
Solution Approach 1:
The patent relocates the control circuit unit from the radial outer circumferential surface to the axial end surface of the motor case. This dimensional shift allows the control circuit to be integrated without increasing the radial size of the motor, while still maintaining close integration for efficient power supply.
3Use of energy by moving object
If leads are inserted radially into tubular frame, then power supply is achieved, but both axial and radial sizes increase
Solution Approach 1:
The patent changes the lead insertion direction from radial to axial. Leads are now inserted through the axial end surface of the motor case and connected to receiving terminals on the axial end surface of the stator core. This axial arrangement eliminates the need for additional radial space and reduces overall motor volume while maintaining effective power supply.
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
The design effectively reduces cogging torque and physical size by optimizing the stator configuration and lead placement, enabling more compact motor designs while maintaining efficient power supply and distribution.
Implementation Method 1
U-shaped segments inserted into the slots in parallel with the central axis in such a manner that distal ends of the segments projecting out of the slots are interconnected electrically, thereby forming an SC coil
Data Source
AI summary
A motor includes a motor case, and a rotor and a stator, which are disposed in the case. The case has a tubular portion, a front cover mounted to an axial end of the portion, and a rear cover mounted to the other axial end of the portion. The rotor has a rotary shaft and the stator includes a plurality of teeth, which extend toward a central axis of the shaft and are circumferentially disposed at equal intervals. Between each circumferentially adjacent pair of the teeth, a slot extending toward the axis is formed. In each slot, a U-shaped segment is inserted in parallel with the axis. The distal ends of the segments projecting out from the slots are electrically interconnected, thereby forming an SC coil including the segments disposed circumferentially. The SC coil includes a receiving terminal, and the terminal includes leads extending in parallel to the axis.