Motor, compressor, and method of manufacturing a motor
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Solution Overview
Problem
Existing motors with cylindrical segmented stators face issues with slot insulators falling off the stator core segment during winding, as they are insufficiently secured.
Innovation Solution
The implementation of an electrical insulation body with a first and second insulation part, and a connection part that includes a groove or fitting mechanism to secure the insulation parts to the stator core segment, preventing them from falling off during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If slot insulators are merely inserted between slit portions and stator core segment, then the structure is simple and easy to manufacture, but the slot insulators are insufficiently secured and may fall off during winding
Solution Approach 1:
The patent applies preliminary action by pre-securing the slot insulator to the stator core segment before the winding process begins. The clipping member is attached to the insulator in advance, creating a predetermined connection that prevents the insulator from falling off during subsequent winding operations. This resolves the contradiction by maintaining manufacturing simplicity while ensuring reliability through advance preparation.
Solution Approach 2:
The clipping member serves as an intermediary element between the slot insulator and the stator core segment. Instead of directly securing the insulator to the core segment, the clipping member mediates the connection by engaging with both components. This intermediary approach maintains ease of manufacture while achieving reliable securing, as the clipping member can be easily attached and provides effective mechanical retention.
2Productivity
If slot insulators are merely inserted between slit portions and stator core segment, then the assembly process is quick and simple, but the slot insulators may fall off when winding is being performed
Solution Approach 1:
The clipping member is attached to the slot insulator as a preliminary action before the insulator is installed onto the stator core segment. This advance preparation ensures that the insulator is pre-secured with a retention mechanism, preventing it from falling off during winding while maintaining quick assembly. The preliminary attachment of the clipping member resolves the contradiction between assembly speed and reliability.
Solution Approach 2:
The clipping member acts as an intermediary that provides secure retention without complicating the assembly process. By introducing this intermediate component, the system achieves both quick assembly (through simple insertion) and reliable securing (through the clipping mechanism). The intermediary clipping member bridges the gap between speed and reliability requirements.
3Reliability
If a secure attachment mechanism is implemented for slot insulators, then the insulators are less likely to fall off during manufacturing, but the device complexity increases
Solution Approach 1:
The clipping member serves as a simple intermediary component that provides secure attachment without significantly increasing device complexity. The clipping member has a straightforward structure that engages with the slot insulator and stator core segment, achieving reliable securing while adding minimal structural complexity. This resolves the contradiction by using a simple mediating element rather than a complex attachment system.
Solution Approach 2:
The attachment system is segmented into distinct functional components: the slot insulator, the clipping member, and the stator core segment. This segmentation allows each component to be optimized independently - the clipping member can be designed as a simple, dedicated retention element without complicating the overall structure. The segmented approach achieves reliable securing while maintaining structural simplicity.
Data Source
AI summary
In an electric motor (310), an electrical insulation body (70) includes a first insulation part (71), a second insulation part (72), and a third insulation part (73). The third insulation part includes a first side surface insulation body (731) disposed on a first side surface of a tooth base part (842) of a stator tooth (84) on the first side in a circumferential direction (DX), a second side surface insulation body (732) disposed on a second side surface of the tooth base part of the stator tooth on a second side in the circumferential direction, and a connection part (733) that connects the first side surface insulation body and the second side surface insulation body. The connection part is disposed on the first side in the axial direction with respect to the tooth base part while being in contact with a first insulation part.