Stacked Stator Coil Lead Routing to Prevent Rotor Wear
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Solution Overview
Problem
The existing motor designs face issues with wear of the leads due to contact with the rotor, as the leads are often arranged in the air gap between the rotor and the stator.
Innovation Solution
The motor design incorporates a stator with coil units stacked axially, separated by nonmagnetic spacers, and leads that are arranged to extend between stator cores of different coil units, avoiding the air gap between the rotor and stator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the leads are arranged in the air gap between the rotor and the stator, then the leads can be easily connected to the coil units, but the rotor contacts the leads causing wear
Solution Approach 1:
The patent extracts the leads from the air gap region and relocates them to extend between stator cores of adjacent coil units. This separation removes the harmful interaction between rotor and leads while maintaining electrical connectivity function.
Solution Approach 2:
The leads are redirected from a radial arrangement in the air gap to an axial arrangement between stator cores. This dimensional change in lead routing eliminates contact with the rotor while preserving electrical connection functionality.
2Reliability
If the leads extend between stator cores of coil units, then contact with the rotor is limited, but the leads may displace between coil units
Solution Approach 1:
A nonmagnetic body is introduced as an intermediary component between coil units. This mediator provides a stable pathway for lead routing and includes engagement portions that secure the leads, preventing displacement while maintaining the benefit of reduced rotor contact.
3Volume of moving object
If the motor operates with stacked coil units, then the motor achieves compact axial design, but vibration may cause lead movement and breaking
Solution Approach 1:
The nonmagnetic body with engagement portions provides beforehand protection for the leads by securing them in place before vibration occurs. This preventive measure cushions against lead displacement and breaking caused by motor vibration during operation.
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 design effectively limits contact between the rotor and the leads, reducing wear and enhancing the motor's operational reliability and efficiency.
Implementation Method 1
a coil including an annular winding wound about the rotation axis, the stator core being arranged to surround at least part of the winding of the coil
Data Source
AI summary
A motor includes a stator having stacking coil units with a nonmagnetic body arranged between, and a rotatable rotor. Each of the coil units includes a coil, and a stator core. The coil includes an annular winding. The stator core is arranged to surround at least part of the winding. The stator core includes projections formed on axial ends of the stator core, alternately arranged in a circumferential direction, and projecting radially toward the rotor from the axial ends. The coil includes the winding and two leads extending from the winding. At least one of a first and a second of the two leads extends between stator cores of two of the coil units. A magnet pole is arranged in one of inner and outer circumferential portions of the stator core, and the first and second leads are arranged in an other one of inner and outer circumferential portions.