Segmented Motor Insulator Ribs Strength
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Solution Overview
Problem
Existing insulators in motors face challenges with maintaining strength and stability when thickness is reduced to improve the space factor, leading to potential deformation and poor fitting with magnetic tooth portions.
Innovation Solution
The design includes a thin insulator with a first and second member combination, featuring overlapping portions with varying thicknesses and ribs to enhance strength and stability, allowing for secure mounting and reduced deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the thickness of the insulator is reduced to improve the space factor of coils, then the space for accommodating coils is increased, but the strength of the fitting portions is decreased and the insulator may be easily deformed
Solution Approach 1:
The insulator is divided into a first insulating member and a second insulating member that are fitted together. This segmentation allows the overall insulator thickness to be reduced while maintaining sufficient strength in the fitting portions, as each member can be optimized independently for both thickness and structural integrity.
Solution Approach 2:
The insulator employs varying thickness distribution, with thicker fitting portions designed specifically for strength and thinner other portions for space optimization. This local quality differentiation allows the insulator to meet both strength requirements in critical areas and space factor improvements in non-critical areas.
2Volume of moving object
If the thickness of the insulator is reduced to improve the space factor of coils, then the space for accommodating coils is increased, but the insulator may not stably hold a constant shape
Solution Approach 1:
By segmenting the insulator into two members with interlocking fitting portions, the design achieves both reduced overall thickness and enhanced shape stability. The fitting portions are specifically designed to prevent deformation and maintain constant shape during assembly and operation.
Solution Approach 2:
The insulator features localized thickness variation where fitting portions maintain sufficient thickness for shape stability while other portions are thinned to improve space factor. This local quality approach ensures shape stability is maintained in critical areas without sacrificing overall space optimization.
3Volume of moving object
If the thickness of the fitting portions is reduced to match the thickness of other portions, then the overall insulator thickness is reduced, but the fitting portions become thinner than required for adequate strength and insulation performance
Solution Approach 1:
The insulator is segmented into two members with overlapping fitting portions. This segmentation enables the fitting portions to have greater thickness than the other portions, ensuring adequate insulation performance and reliability while the overall insulator maintains reduced thickness for improved space factor.
Solution Approach 2:
The insulator implements non-uniform thickness distribution where fitting portions are locally thickened to ensure reliable insulation performance and structural integrity, while other portions are thinned to reduce overall insulator thickness and improve space factor. This local quality differentiation resolves the contradiction between overall thickness reduction and localized performance requirements.
Data Source
AI summary
An armature includes an insulator mounted on a tooth portion around which a conducting wire is wound. A pair of a first member and a second member, which are combined so as to abut each other, is provided. The first member includes a first end wall which covers an upper side end in the axial direction of the tooth portion and a pair of first side walls which partially cover both side portions of the tooth portion. A first overlap portion is provided on a tip portion of the first side wall. A plurality of ribs extending so as to be parallel or substantially parallel to the winding direction of the conducting wire is disposed on an outer surface of the first overlap portion.