Stator Booster Structure for Compact Motor Wire Bending
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Solution Overview
Problem
The straight length extension of stator wires from the stator core in electric motors limits packaging space and reduces motor performance, particularly in applications like traction motors of electric vehicles.
Innovation Solution
The introduction of a stator booster with a booster back-iron and booster teeth that extend radially inward, encapsulated by an electrically insulating material, allows stator wires to bend within booster slots, reducing the need for straight extensions and enhancing electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stator wires are extended in a straight line parallel to the central axis before bending, then the integrity of insulating materials is maintained, but the total length of the stator core is limited which reduces motor power
Solution Approach 1:
The stator is divided into two segments: the original stator core and an additional stator booster. The stator booster includes booster teeth with booster slots that provide an alternative path for wire routing. This segmentation allows the wire to bend within the booster slot rather than requiring a long straight extension, thereby maintaining insulating material integrity while enabling a longer effective stator core length for improved motor power.
Solution Approach 2:
The invention utilizes the radial dimension by extending booster teeth radially inward from the booster back-iron. The booster slots are formed between these radially extending teeth, creating a three-dimensional wire routing path that combines axial and radial components. This dimensional approach allows wire bending to occur within the radial depth of the booster teeth rather than requiring extended axial straight portions.
2Volume of stationary object
If the straight length extension of stator wires is reduced to increase packaging space, then motor performance is improved, but the integrity of insulating materials may be compromised
Solution Approach 1:
The stator is divided into the original stator core and an additional stator booster. The stator booster includes booster teeth with booster slots that provide an alternative path for wire routing. This segmentation allows the wire to bend within the booster slot rather than requiring a long straight extension, thereby maintaining insulating material integrity while enabling a longer effective stator core length for improved motor power.
Solution Approach 2:
The stator booster acts as an intermediary structure between the stator core and the wire routing path. The booster teeth and booster slots provide a mediating structure that facilitates wire bending while maintaining insulation integrity. The insulating material is applied to the booster teeth and within the booster slots, serving as an intermediary protective layer that enables compact wire routing without compromising insulation.
3Power
If a stator booster is added to enable wire bending within booster slots, then motor power increases without increasing size, but the device complexity increases
Solution Approach 1:
The stator booster is merged with the stator core to form an integrated stator assembly. The booster back-iron is positioned adjacent to the stator core with booster teeth extending radially inward to align with core teeth. This merging creates a unified magnetic circuit and structural unit that enables wire bending functionality without requiring separate, complex wire routing mechanisms.
Solution Approach 2:
The stator booster serves multiple functions: it provides additional magnetic path length for improved motor power, creates booster slots for wire bending and routing, and maintains structural integrity through the booster back-iron. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity while achieving the power enhancement goal.
Data Source
AI summary
A motor includes a stator core and a stator booster. The stator booster includes a booster back-iron and a plurality of booster teeth. The booster back-iron includes a first end surface that abuts a first end surface of the stator core's back-iron for electrical communication therewith. The booster teeth extend radially inward from the booster back-iron and are spaced apart from one another in a circumferential direction about the central axis to define a plurality of booster slots that align with slots of the stator core. A first end surface of each booster tooth abuts a first end surface of a corresponding tooth of the stator core for electrical communication therewith. An electrically insulating material encapsulates opposite sides of each booster tooth that define the booster slots and a second end surface of each booster tooth that is opposite the first end surface of that booster tooth.