Stator Assembly with Hall Sensor Bracket and Insulation Coating
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Solution Overview
Problem
Existing stator designs for motors require insulators or insulation films, leading to increased manufacturing costs, material waste, and limitations in electromagnetic characteristics, particularly when connecting hall sensors, due to complex manufacturing processes and inadequate connection methods.
Innovation Solution
A stator assembly with a rounded base and radially formed teeth, featuring an insulation coating layer on the surface except the inner face and holes, and connection parts with brackets and protrusions that securely connect a hall sensor assembly, reducing material usage and enhancing manufacturing simplicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulators or insulation films are applied to insulate the stator core teeth, then insulation is achieved, but manufacturing costs increase and manufacturing complexity increases
Solution Approach 1:
The stator core sheets themselves provide insulation through their inherent material properties and structural arrangement. The insulating resin coating is applied only where necessary (on the outer circumferential surface) rather than requiring additional insulator components, allowing the stator core to insulate itself without external insulating elements.
Solution Approach 2:
The invention extracts and removes the separate insulator component from the stator assembly. By integrating insulation functionality directly into the stator core structure through resin coating, the need for distinct insulator parts is eliminated, simplifying the overall structure and reducing manufacturing steps.
2Reliability
If insulators are connected to the stator core, then insulation is achieved, but the number of parts increases and manufacturing complexity increases
Solution Approach 1:
The insulation function is merged with the stator core structure itself. The insulating resin coating is integrated directly onto the stator core sheets, combining the structural and insulating functions into a single unified component rather than separate parts.
Solution Approach 2:
Separate insulator components are extracted and removed from the design. The invention eliminates the need for distinct insulator parts by incorporating insulation directly into the stator core construction.
3Adaptability or versatility
If connection parts are formed on stator core sheets, then connection functionality is achieved, but material waste increases due to scraps
Solution Approach 1:
The connection functionality is segmented and integrated directly into the stator core sheet structure. Connection parts are formed as inherent features of the stator core sheets themselves rather than as separate components, allowing direct attachment of the hall sensor assembly to the stator core without additional connection parts.
4Adaptability or versatility
If L-shaped connection parts are attached to the stator core, then connection functionality is achieved, but welding is required which does not guarantee firm connection
Solution Approach 1:
The stator core structure itself provides the connection functionality through integrated connection parts. The hall sensor assembly is directly attached to the stator core sheets without requiring separate L-shaped connection parts or welding processes, eliminating connection reliability issues.
Data Source
AI summary
Disclosed herein is a stator assembly for a motor including: a stator core which includes a rounded base having a plurality of first holes formed in the vertical direction and a plurality of teeth radially formed on the outer circumferential surface of the base; an insulation coating layer formed on the entire surface of the stator core except the inner face of the base and the periphery of the first hole; and one or more connection parts connected to the rounded base.