Motor Stator Insulating Space Under High Pressure Molding
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Solution Overview
Problem
Conventional motor stators with toroidal windings face challenges in maintaining an insulating space between coils and crossover wires, especially under high pressure molding resin, which can cause the crossover wires to touch and require cumbersome insulating procedures.
Innovation Solution
A motor stator design featuring an annular stator core with insulating grooves and guide posts that maintain an insulating space between coils and crossover wires, even under high pressure molding, using a toroidal winding structure and thermosetting resin molding to prevent deformation and ensure reliable insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a groove is provided to accommodate a crossover wire, then the crossover wire can be prevented from touching the coil, but the insulating space cannot be maintained under high pressure molding resin
Solution Approach 1:
A resin layer is introduced as an intermediary substance between the crossover wire and the coil. This resin layer fills the groove and maintains a stable insulating space that can withstand high pressure molding forces, preventing direct contact between the crossover wire and coil while maintaining structural integrity during the molding process
2Reliability
If insulating tape is stuck to coils and crossover wires, then insulation can be achieved, but the manufacturing process becomes cumbersome
Solution Approach 1:
The molding resin serves a dual function: it both insulates the crossover wire from the coil and structurally maintains the insulating space simultaneously. This self-service approach eliminates the need for separate insulating tape application steps, as the resin performs both insulation and structural support functions in one process
3Ease of manufacture
If the stator core structure is simplified, then manufacturing is easier, but the structure cannot withstand high pressure molding resin
Solution Approach 1:
The solution combines the stator core structure with the molding resin to create a composite system. The resin is not merely a filling material but becomes an integral structural component that reinforces the stator core, allowing it to withstand high molding pressures while maintaining overall structural simplicity
Data Source
AI summary
A motor stator is disclosed. Each of a first phase, second phase and third phase of three-phase winding has multiple toroidal coils and crossover wires connecting the coils. The crossover wire of the first phase runs inside the second phase coil and the third phase coil. The crossover wire of the second phase runs over the first phase coil with a guide by guide posts and runs inside the third phase coil. The crossover wire of the third phase runs over the first phase coil and the second phase coil with a guide by the guide posts.