Compressor Motor Stator Insulation Segmentation
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Solution Overview
Problem
Conventional stator designs for compressor motors require separate molds for upper and lower insulators, leading to increased plastic material usage and reduced coil winding spaces due to fixed insulator thickness, making it difficult to accommodate varying stator core heights and complicating the assembly process.
Innovation Solution
A stator configuration featuring upper and lower insulators that partially cover the stator core with inserted insulation films, which are securely locked by locking protrusions, allowing for adjustable thickness and reduced material usage, and enabling easy assembly without the need for custom molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If upper and lower insulators are made through plastic injection molding with predetermined thickness, then insulation between coils and stator core is ensured, but the slots between teeth become narrow reducing coil winding spaces
Solution Approach 1:
The insulator system is segmented into three components: upper insulator, lower insulator, and insulation films. The insulation films are inserted into slots between teeth to provide insulation, while the upper and lower insulators cover the top and bottom surfaces. This segmentation allows thin insulation films to be used in slots rather than thick molded insulators, enlarging coil winding spaces while maintaining insulation reliability.
Solution Approach 2:
Different insulation solutions are applied to different locations: thin insulation films are used in the slots between teeth where space is critical, while thicker upper and lower insulators are used on the top and bottom surfaces where space is less constrained. This local differentiation optimizes both insulation performance and coil winding space.
2Reliability
If upper and lower insulators are formed to cover the entire teeth of the stator core, then complete insulation is achieved, but a quantity of plastic material used becomes increased
Solution Approach 1:
The insulation function is extracted from the bulk plastic insulators and implemented through thin insulation films inserted into slots. This reduces the volume of plastic material required for the upper and lower insulators while maintaining complete insulation coverage through the combination of all three insulation components.
Solution Approach 2:
Thin insulation films are used instead of thick plastic insulators in the slots between teeth. These thin films provide adequate insulation with minimal material consumption, significantly reducing the quantity of plastic material required while maintaining insulation effectiveness.
3Adaptability or versatility
If separate molds are manufactured for upper and lower insulators to accommodate varied stator core heights, then customization for different heights is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The upper and lower insulators are designed with universal dimensions that can accommodate various stator core heights. The adaptability to different heights is achieved not through custom molds but through the modular insulation film system that can be adjusted in thickness or number of layers, making the insulator molds reusable across different motor specifications.
Solution Approach 2:
The insulation system becomes dynamic and adjustable through the use of insulation films that can be selected or configured based on the specific stator core height requirement. This allows the same insulator mold to serve multiple height specifications, eliminating the need for separate molds for each height variation.
4Volume of moving object
If insulation films are inserted between upper and lower insulators, then coil winding spaces are enlarged, but the assembly process becomes more complex
Solution Approach 1:
The insulation films are pre-inserted into the slots between teeth before the upper and lower insulators are assembled. The insulators are designed with guiding structures and positioning features that facilitate the preliminary insertion of insulation films, making the assembly process straightforward despite the additional component.
Solution Approach 2:
The upper and lower insulators serve as intermediaries that hold and secure the insulation films in place. The insulators provide a structured framework that guides the insulation films into proper positions and maintains them during the assembly process, simplifying the overall assembly despite the multi-component nature of the insulation system.
Data Source
AI summary
A stator for a compressor motor that has a structure in which the ends of insulation films inserted into slots of a stator core are supportedly locked to locking protrusions formed on upper and lower insulators for insulating the upper and lower sides of the stator core, thereby allowing the insulation films to be securely supported and providing easy assembling process for the insulation film and the upper and lower insulators.