Motor Stator Insulation Frame for High Copper Fill and Lower Material Use
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing insulation devices for motor stators face challenges in balancing the copper wire space factor and manufacturing cost, with conventional designs either compromising on one or the other due to material usage and structural limitations.
Innovation Solution
The use of insulating frames with support ends extending in the same direction to support insulating wrapping layers, allowing for a tubular structure that reduces material consumption and maintains a high copper wire space factor while minimizing manufacturing costs, and the incorporation of a pressing mechanism to secure the wrapping layers effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional insulation devices use complete frame structures to support insulating paper, then the structural stability and support strength are improved, but the material consumption increases and copper wire space factor decreases
Solution Approach 1:
The insulating frame is segmented into only two support ends rather than a complete frame structure. These support ends are positioned at key locations to provide necessary support while minimizing material usage. The segmentation allows the frame to maintain structural stability without requiring continuous material coverage throughout the entire frame perimeter.
Solution Approach 2:
The invention extracts only the essential supporting parts (two support ends) from the complete frame structure. By removing unnecessary frame segments, the design achieves the minimum material consumption required to maintain adequate support strength for the insulating paper and stator windings.
2Stability of the object's composition
If conventional insulation devices use complete frame structures to support insulating paper, then the structural stability is improved, but the copper wire space factor decreases
Solution Approach 1:
The frame structure is segmented into discrete support ends rather than continuous material, creating gaps where copper wires can be positioned. This segmentation maintains structural stability at key support points while maximizing the available area for copper wire winding.
Solution Approach 2:
The support ends are positioned strategically in three-dimensional space to provide structural stability without occupying excessive two-dimensional area that would reduce copper wire space factor. The vertical positioning and spacing of support ends create stability while preserving horizontal winding area.
3Strength
If insulating frames use more material to ensure sufficient strength, then the support strength is improved, but the manufacturing cost increases
Solution Approach 1:
The design extracts only the minimum necessary material (two support ends) required to achieve adequate support strength. This reduction in material quantity directly lowers manufacturing costs while maintaining the essential function of supporting insulating paper and stator windings during assembly and operation.
Solution Approach 2:
The invention changes the structural parameters of the insulating frame from a complete continuous structure to a minimal discrete structure with only two support ends. This parameter change optimizes the strength-to-cost ratio by using the minimum material necessary to achieve the required support function.
Data Source
AI summary
Embodiments of the present disclosure include insulating devices, motor stators, and motors. The insulating device comprises at least one insulating frame and at least one insulating wrapping layer; the insulating frame has at least two support ends with the same orientation and arranged at intervals; the insulating wrapping layer is a cylindrical structure, and at least one open end of the cylindrical structure wraps the at least two support ends on the insulating frame and is supported by the support ends to form a winding space. The insulating device can balance the copper wire space factor and the manufacturing cost.