Motor Stator Coil Segmentation for Accurate Busbar Connection
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Solution Overview
Problem
In motors with stator coils, there is a technical difficulty in properly forming multiple connection systems due to the potential confusion between winding ends of the stator coil and busbars, leading to incorrect connections.
Innovation Solution
The motor design includes a stator with an annular core and teeth, where coils are wound around the teeth with an insulator in between, and separate busbars connected to distinct coil groups, with specific steps for forming and connecting the coils to prevent confusion, such as forming a first coil winding, hooking the wire end to form a lead line, and winding the wire over the first coil to form a second coil, ensuring each coil end is connected to a specific busbar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two conductors are drawn as winding ends from one stator core using conventional coiling method, then the stator coil can be formed, but the conductors may be confused and connected to wrong busbars, causing incorrect connection systems
Solution Approach 1:
The patent divides the stator core into multiple independent sections, each with its own insulator and connection system. By segmenting the coiling process into separate first coil and second coil groups with distinct insulators, the patent prevents confusion between conductors from different sections, ensuring accurate connection to respective busbars while maintaining ease of manufacture.
Solution Approach 2:
The patent introduces insulators as intermediary elements between the stator core and busbars. These insulators serve as mediators that guide and distinguish the conductors, preventing direct confusion between winding ends from different sections. The insulator acts as a physical and functional intermediary that ensures each conductor group connects to the correct busbar, thereby improving connection accuracy without complicating the manufacturing process.
2Reliability
If multiple connection systems are formed in a motor, then power supply reliability is improved, but the complexity of properly forming and connecting the systems increases
Solution Approach 1:
The patent segments the connection system into multiple independent first coil groups and second coil groups, each with its own insulator and busbar connections. This segmentation allows multiple connection systems to be formed with clear physical separation, reducing the complexity of managing and connecting multiple systems while maintaining high power supply reliability through redundancy.
Solution Approach 2:
The patent implements preliminary actions by pre-positioning insulators on the stator core before coil winding. This preliminary placement of insulators establishes clear boundaries and guidance paths for conductors from the outset, simplifying the subsequent coil formation and connection processes. By preparing the insulator positions in advance, the patent reduces the complexity of forming multiple connection systems while ensuring accurate connections.
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 allows for clear differentiation and secure connection of coil ends to their respective busbars, preventing confusion and facilitating the formation of multiple connection systems, ensuring reliable power supply even if one connection system fails.
Implementation Method 1
an insulator, at least part of which is positioned between the teeth and the coils
Data Source
AI summary
A motor includes a rotor having a shaft disposed along a central axis extending in a vertical direction; and a stator opposed to the rotor in a radial direction with a gap therebetween. The stator includes: an annular core back extending in a circumferential direction; a plurality of teeth extending from the core back in the radial direction; a plurality of coils formed of a conductive wire wound around the teeth, the coils forming a plurality of connection systems; and an insulator, at least part of which is positioned between the teeth and the coils. The coils include: a first coil wound around the teeth via the insulator; and a second coil wound around the teeth via the first coil and the insulator.