Stator Bobbin with Bent Flange for Winding Space
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional stators in rotating electrical machines face challenges in maximizing the winding space factor due to limitations in the design of the outer and inner cores, which affects the performance and size of the motor.
Innovation Solution
The stator design incorporates a cylindrical bobbin with a flange part featuring multiple bent parts and a constant thickness, allowing for increased winding space while preventing interference with the outer core projections, and the outer and inner cores are made from the same sheet metal material with specific positional relationships to optimize magnetic gap and reduce size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of winding wires or turns is increased to improve space factor, then the space factor improves, but the bobbin structure becomes more complex and may interfere with the outer core
Solution Approach 1:
The bobbin is divided into a cylindrical body part and a flange part with multiple bent parts (first, second, and third bent parts). This segmentation allows each part to serve specific functions: the cylindrical body part accommodates winding wires, while the flange part with bent sections manages spatial relationships with the outer core projections, enabling increased winding capacity without interference
Solution Approach 2:
The flange part extends radially outward from the cylindrical body part, utilizing the radial dimension to accommodate bent parts that navigate around outer core projections. This dimensional approach allows the winding structure to expand in space without increasing the axial height, thereby increasing space factor while avoiding interference with the outer core
2Volume of moving object
If the stator size is reduced to achieve downsizing, then the motor size decreases, but the winding space factor may be compromised
Solution Approach 1:
The flange part with multiple bent parts utilizes radial and circumferential dimensions to accommodate winding wires and navigate around outer core projections. This multi-dimensional winding arrangement maximizes the use of available space within the stator, allowing increased winding space factor without increasing the overall stator volume, thereby enabling downsizing while maintaining performance
3Reliability
If the flange part is designed to prevent interference with outer core projections, then interference is avoided, but the winding space may be limited
Solution Approach 1:
The flange part is segmented into multiple bent parts (first, second, and third bent parts) that are strategically positioned to navigate around outer core projections. This segmentation allows the winding structure to adapt to the presence of projections while maintaining adequate winding space, as each bent part can be optimized for its specific spatial relationship with the projections
Solution Approach 2:
The bent parts utilize the circumferential dimension to wrap around outer core projections, effectively using the projections as part of the winding path rather than treating them as obstacles. This approach maintains reliability by preventing interference while preserving winding space through clever use of three-dimensional space
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 configuration enhances the winding space factor, improves motor performance, and allows for downsizing of the stator, maintaining the width of the teeth while ensuring efficient electromagnetic induction.
Implementation Method 1
a bobbin having a cylindrical body part around which winding wires are wound
Data Source
AI summary
A stator includes: a stator core having an almost annular outer core and an inner core arranged inside the outer core; and a bobbin having a cylindrical body part around which a winding wire is wound and a flange part that is formed so as to rise up from the cylindrical body part, with a plurality of bent parts and an edge part.