Motor Stator Bobbin with Triangular Projecting Portions
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Solution Overview
Problem
Conventional stator bobbins for motors face challenges in maintaining mechanical strength and preventing deformation or breakage when winding conductors are wound, while also ensuring a large volume for the winding conductor and facilitating the fitting of the magnetic pole constituent member into the yoke.
Innovation Solution
The stator design incorporates a bobbin with a projecting portion at the first connecting portion of the flange, increasing the thickness and mechanical strength of the first flange portion, and includes stopper portions and ribs to enhance mechanical strength and facilitate fitting, while maintaining a large volume for the winding conductor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the thicknesses of the flange portions of the bobbin are reduced to increase the volume for the winding conductor, then the volume occupied by the winding conductor is increased, but the bobbin may be deformed or broken due to stress when the winding conductor is wound
Solution Approach 1:
The bobbin design applies local quality by making the flange portions thinner only in specific regions where it is necessary for increasing winding conductor volume, while maintaining adequate thickness in other critical areas. The first flange portion has a thinner region to maximize winding space, but the second flange portion and connecting sections maintain sufficient thickness to provide mechanical support and prevent deformation during the winding process.
2Volume of moving object
If the thickness of the flange portions of the bobbin is reduced to increase the volume for the winding conductor, then the volume occupied by the winding conductor is increased, but the electrically insulating effect of the bobbin may be reduced
Solution Approach 1:
The bobbin is constructed using composite material principles by combining the insulating material body with additional insulating structures. The insulating material forms the main bobbin structure, while the first and second flange portions extend from opposite ends of the cylindrical portion to provide enhanced insulating barriers. This composite structure ensures adequate electrical insulation even when the flange portions are thinned in certain areas to increase winding volume.
3Volume of moving object
If the thickness of the flange portions of the bobbin is reduced to increase the volume for the winding conductor, then the volume occupied by the winding conductor is increased, but the bobbin with the winding conductor wound therearound may not be able to be fitted with the corresponding pole column
Solution Approach 1:
The bobbin design incorporates preliminary action by pre-forming the first and second flange portions that extend from the cylindrical portion before the winding process. These flange portions are designed with appropriate dimensions and positioning to facilitate the subsequent fitting of the pole column. The flange portions provide preliminary structural support and alignment features that enable easy assembly, even when the flange thickness is reduced in certain areas to increase winding volume.
Data Source
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AI summary
A projecting portion 23h is integrally provided at a first connecting portion 23e of a bobbin 23. The projecting portion 23h has a triangular cross-section taken in an orthogonal direction orthogonal to a laminating direction of the steel plates 21 and parallel to magnetic steel plates 21. The section of the projecting portion is geometrically similar in shape to a cross-section of a fitting recessed portion 7a taken in the orthogonal direction. The cross-section of the projecting portion 23h is substantially the same in size as or slightly smaller than the cross-section of the fitting recessed portion 7a. With this arrangement, when one ends of six magnetic columns 13 of a magnetic pole constituent member 9 are brought into engagement with six fitting recessed portions 7a, projecting portions 23h passes through the fitting recessed portions 7a and come out of the fitting recessed portions 7a.