Stator Assembly Insulation Coating for Hall Sensor Positioning
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Solution Overview
Problem
Existing stator assemblies in motors face issues with uneven outer diameter surfaces of teeth leading to poor insulating performance, increased resin moldings, complex mold designs, and restricted hall sensor positioning, which affect magnetic flux and manufacturing costs.
Innovation Solution
A stator assembly with an insulation coating layer on the outer diameter surfaces of the teeth and selectively inserted insulation films into slots, allowing for enhanced insulating performance without reducing slot space, and enabling flexible hall sensor positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If teeth insulating parts are made thicker to improve insulating performance, then insulating performance is improved, but slot space is reduced and magnetic flux characteristics deteriorate
Solution Approach 1:
The insulating structure is divided into two segments: thin insulating parts integrated with the teeth and separate insulation films inserted into the slots. This segmentation allows the insulating films to provide additional insulation in the slot region without increasing the thickness of the teeth insulating parts, thereby preserving slot space while improving insulating performance.
Solution Approach 2:
Insulation films are introduced as an intermediary element between the coil and the slot. These films provide the necessary insulating performance in the slot region without requiring the teeth insulating parts to be thicker, thus resolving the conflict between insulation requirements and slot space constraints.
2Ease of manufacture
If hall sensor connecting part is formed at one portion of the insulator, then manufacturing is simplified, but joining position of hall sensor part is restricted
Solution Approach 1:
The insulator is designed with multiple hall sensor connecting parts at different positions, making it universally adaptable to various hall sensor placement requirements. This multi-functional design allows the same insulator structure to serve multiple positioning purposes without requiring different insulator designs.
Solution Approach 2:
Instead of adding complexity in the planar dimension, the solution provides connecting parts at different radial positions around the insulator. This dimensional arrangement allows flexible hall sensor positioning while maintaining a relatively simple molded structure.
3Adaptability or versatility
If connector bushings and hall sensor connecting part are selectively formed on the insulator, then functional integration is improved, but mold becomes complicated and manufacturing costs rise
Solution Approach 1:
The insulator structure is segmented into different functional regions: connector bushings at the inner circumferential surface and hall sensor connecting parts at the outer circumferential surface. This segmentation allows each component to be formed in its optimal location without requiring a highly complex integrated mold design.
Solution Approach 2:
Different portions of the insulator are given different functional qualities: the inner circumferential surface has connector bushings for electrical connection, while the outer circumferential surface has hall sensor connecting parts for sensor mounting. This local differentiation achieves functional integration without uniformly complicating the entire insulator structure.
Data Source
AI summary
Disclosed therein is a stator assembly including: a stator core (10) having a round base, a plurality of teeth radially formed along the outer circumferential surface of the base, and at least one connector bushing formed on the inner circumferential surface of the base; and an insulation coating layer (20) formed on the surface of the stator core, wherein the insulation coating layer (20) is coated to the outer diameter surfaces of the teeth of the stator core.