Split-Core Stator Wiring Layout With Integrated Coil Connectors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing motor stators face challenges with complex wiring structures, increased manufacturing costs due to the use of separate components like printed circuit boards and tubes for insulation, and potential gaps and vibrations between wires, leading to inefficiencies and higher material usage.
Innovation Solution
A stator design featuring split cores with integrated power and neutral line connectors, insulators with wire guides, and connection members to facilitate easy wiring and maintain insulation distances, reducing material usage and preventing wire interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate components (PCBs, tubes) are used for wiring and insulation, then insulation between stator core and stator coil is achieved, but manufacturing cost increases and device complexity increases
Solution Approach 1:
The patent combines the insulation function and wiring function into a single integrated insulator structure. The insulator includes built-in wire guides and connectors that directly guide and connect the stator coil wires to the power supply, eliminating the need for separate PCBs and protective tubes. This merging reduces device complexity while maintaining insulation reliability.
Solution Approach 2:
The insulator is designed as a multi-functional component that simultaneously provides electrical insulation, mechanical support for wire routing, and electrical connection functions. The wire guides and connectors are integrated into the insulator body, allowing a single component to perform multiple functions that previously required separate parts.
2Reliability
If separate components (PCBs, tubes) are used for wiring and insulation, then insulation is ensured, but manufacturing cost increases
Solution Approach 1:
By merging multiple functions into a single insulator component, the patent reduces the total number of parts that need to be manufactured, stored, and assembled. This integration simplifies the manufacturing process and reduces material costs while maintaining the necessary insulation and wiring functions.
3Volume of moving object
If wires are closely arranged in stator coil, then space utilization is improved, but gaps and vibrations between wires occur
Solution Approach 1:
The wire guides integrated into the insulator act as intermediaries that maintain optimal spacing between adjacent wires in the stator coil. These guides ensure wires are properly positioned and spaced, preventing gaps and vibrations while maintaining efficient space utilization within the stator assembly.
4Reliability
If complex wiring structure is used, then insulation is ensured, but time and efforts for wiring increase
Solution Approach 1:
The insulator is pre-configured with integrated wire guides and connectors in predetermined positions. This preliminary arrangement of wiring paths and connection points simplifies the actual wiring process, as wires can be directly routed through the guides and connected to terminals without requiring complex assembly steps or additional insulation measures.
Data Source
AI summary
A stator of a motor include a first split core including first teeth, a second split core including second teeth and facing the first split core to define a rotor accommodating hole with the first split core, a first insulator disposed at the first split core, a second insulator disposed at the second split core, phase coils that are wound around the first teeth and the second teeth, respectively, and are configured to connect to a three-phase alternating current (AC) power supply, power line connectors that are disposed at the first insulator and configured to connect the phase coils to the three-phase AC power supply, and a neutral line connector that is disposed at the second insulator and connected to the phase coils.