Brushless Motor Stator Coating with Case Receiving Part
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Solution Overview
Problem
The existing process of coating electric motor stator coils results in excess coating material accumulating at the bottom, obstructing assembly and requiring costly removal, leading to increased man-hours and waste generation.
Innovation Solution
Incorporating a receiving part in the motor case to contain excess coating material, which cures within the case, eliminating the need for removal and enhancing vibration resistance by linking the stator unit and case with the coating material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coating material is dripped to adequately cover the coil, then the coil is sufficiently protected, but excess coating material accumulates at the bottom forming lumps that obstruct assembly
Solution Approach 1:
The case is segmented into a main body and a receiving part (protrusion) that is spatially separated from the coil assembly area. This segmentation allows excess coating material to be directed to a specific receptacle during the coating process, preventing lump formation that would obstruct stator insertion while maintaining adequate coil coverage.
2Ease of operation
If excess coating material is removed by cutting, then assembly obstruction is eliminated, but production time increases and waste is generated
Solution Approach 1:
The receiving part converts the harmful effect of excess coating material (which would normally form obstructive lumps) into a beneficial outcome by providing a designated receptacle that captures and contains the excess material. This eliminates the need for post-coating removal operations, maintaining both ease of assembly and production efficiency while preventing waste generation.
3Ease of manufacture
If a receiving part is added to the case, then excess coating material can be contained, but the case structure becomes more complex
Solution Approach 1:
The receiving part is merged with the case as an integrated structural feature rather than a separate component. The protrusion forming the receiving part is directly formed on the case during case manufacturing, combining the case and receiving part into a single manufactured component. This minimizes structural complexity while enabling effective excess coating material containment.
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 approach reduces man-hours, eliminates waste, and improves product strength and performance by containing excess coating material within the case, allowing for efficient assembly and enhanced vibration resistance.
Implementation Method 1
after collecting the excess coating material in the receiving part included in the end part of the case, the coating material is cured
Implementation Method 2
the coil is fixed to the end part through the coating material in the receiving part. The excess coating material contained in the receiving part in this electric motor links the stator unit and the end part of the case
Data Source
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AI summary
Brushless motor (1) which is an electric motor, is provided with a stator unit (3) inserted in and engaged with case (2). A part of the coating material (21) for coating the coil (17) of the stator unit (3) enters the receiving part (13) formed in the bottom part (2B) of the case (2); and the bottom part (2B) of the case (2) and the coil (17) are linked by this coating material (21). While coating, the coating material (21) is dripped from the opening side of the case (2) with the stator unit (3) in the inserted condition in the case (2).