Stator Insulation Member for Toolless Assembly
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Solution Overview
Problem
Existing electric motor stator assemblies face challenges in securely attaching insulation to components like teeth, which increases assembly costs and is incompatible with automatic winding processes.
Innovation Solution
The introduction of insulation members that can be toollessly coupled to stator assemblies, including caps and hubs, to cover stator teeth and support conduction coils, facilitating automatic winding and reducing assembly costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional insulation materials are used to insulate stator teeth from conduction coils, then electrical insulation is achieved, but assembly complexity increases and tool-based attachment is required
Solution Approach 1:
The insulation member is merged with the cap structure to form an integrated component. The cap includes an insulation member that extends between stator teeth, combining the functions of mechanical support and electrical insulation in a single element that attaches to the stator assembly without requiring separate insulation components or tools
Solution Approach 2:
The cap serves multiple functions simultaneously: it provides mechanical support for conduction coils, electrical insulation between stator teeth and coils, and structural attachment to the stator assembly. This multi-functional design eliminates the need for separate insulation components and simplifies the overall assembly
2Reliability
If traditional insulation methods are used, then electrical insulation is provided, but compatibility with automatic winding processes is lost
Solution Approach 1:
The insulation member is pre-installed on the stator teeth as part of the cap structure before the winding process. This preliminary placement of insulation eliminates the need for manual insulation installation during or after automatic winding, enabling full automation of the coil winding process while maintaining electrical insulation
3Reliability
If traditional insulation components are used, then electrical insulation is achieved, but assembly cost increases
Solution Approach 1:
The insulation member is combined with the cap to form a single integrated component, reducing the total part count and eliminating the need for separate insulation components. This merging reduces material costs, assembly time, and labor requirements, thereby lowering overall assembly cost while maintaining electrical insulation functionality
Data Source
AI summary
A stator assembly includes an annular body extending about a central axis and a plurality of stator teeth extending axially from the annular body and spaced circumferentially about the annular body. The stator assembly includes at least one conduction coil and at least one bobbin configured to support the at least one conduction coil. The at least one bobbin is coupled to a first stator tooth such that the at least one conduction coil extends about the first stator tooth. The stator assembly further includes at least one insulation member configured to couple to a second stator tooth and extend into a slot between the second stator tooth and the at least one conduction coil. The at least one insulation member includes an end wall configured to cover the distal end of the second stator tooth when the at least one insulation member is coupled to the second stator tooth.