Snap-Fit Stator Insulator Assembly for Continuous Coil Winding
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Solution Overview
Problem
The existing stator manufacturing process for rotary electric machines is complicated due to the need for multiple types of insulators and retention mechanisms, which increases the number of components and manufacturing steps, making it costly and inefficient.
Innovation Solution
A stator design featuring magnetic-pole pieces with integrally formed tooth portions and arc-shaped back yokes, using identical resin insulators with snap-fit connections to simplify the assembly and reduce the number of components, allowing for continuous winding and annular arrangement of magnetic-pole pieces without increasing the number of manufacturing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two kinds of insulators with different shapes are used to connect adjacent magnetic-pole pieces, then the magnetic-pole pieces can be connected and rotated, but the number of components increases and the manufacturing process becomes complicated
Solution Approach 1:
The insulator is designed with a universal structure that can connect magnetic-pole pieces at multiple positions along the axial direction. The insulator includes a body with a first insertion hole for receiving a first magnetic-pole piece and a second insertion hole for receiving a second magnetic-pole piece, allowing a single component type to perform multiple connection functions that previously required different shaped insulators.
2Reliability
If retention mechanisms are added to prevent magnetic-pole pieces from displacing in the axial direction, then the magnetic-pole pieces can be securely connected, but the manufacturing process becomes more complicated
Solution Approach 1:
The retention function is merged into the insulator structure itself. The insulator body includes retention protrusions that extend in the axial direction, which engage with grooves on the magnetic-pole pieces to prevent axial displacement. This integration eliminates the need for separate retention mechanisms while maintaining connection stability.
3Volume of moving object
If tooth portions are arranged on the radially inner side in an annular shape, then the structure is compact, but the jumper wires move and cannot be fixed at constant positions
Solution Approach 1:
The insulator is designed with predetermined positions for jumper wires, including wire guide holes that are formed in advance during insulator manufacturing. These guide holes are positioned to receive and secure jumper wires at constant locations, preventing wire movement while maintaining the compact annular arrangement of tooth portions on the radially inner side.
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
This approach results in a high-performance rotary electric machine with reduced manufacturing costs and complexity, achieving a small-sized product without increasing the number of components or manufacturing steps.
Implementation Method 1
The pillar portion has an outer diameter that is not less than an inner diameter of the opened-ring portion in a free state in which no external force is applied. This enables the pillar portion to be fitted to the opened-ring portion through elastic deformation of the resin insulator material, achieving swingable connection between adjacent magnetic-pole pieces.
Data Source
AI summary
Magnetic-pole pieces each equipped with a pair of insulators made of resin are provided with a conductive wire wound continuously via a jumper wire making connection between the magnetic-pole pieces, and are arranged in an annular shape. Each insulator has, at one end in a circumferential direction of an axial-direction end, a snap-fit female portion having an opened-ring portion having an opening, and has, at another end, a snap-fit male portion having a pillar portion extending in the axial direction from a base portion. The adjacent magnetic-pole pieces are connected swingably relative to each other via snap-fit connection by fitting of the pillar portion to the opened-ring portion. A jumper-wire-caught portion at which a jumper wire is caught is provided at least in one location of the connection part where mutual connection is made.