Stator Assembly Insulation Film and Sensor Groove Design
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Solution Overview
Problem
Conventional stator assemblies for motors require increased resin consumption and complex molds for ejection molding, leading to higher material costs and limited flexibility in positioning the hole sensor portion due to integrated insulating structures.
Innovation Solution
A stator assembly with an insulation coating layer on the stator core and an insulation film inserted in slots between teeth, along with a hole sensor portion featuring a coupling groove that can be arbitrarily positioned, reducing resin consumption and allowing flexible sensor placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the teeth insulating portion is formed integrally with the insulator through ejection molding, then insulation is provided, but the thickness of the insulating portion becomes greater than the teeth, reducing slot size and increasing resin consumption
Solution Approach 1:
The insulation structure is divided into two separate components: a thin insulator base and a separate teeth insulating portion that is selectively formed only where needed on the teeth surfaces. This segmentation allows the insulating function to be provided without the entire insulator having uniform thickness, thereby reducing overall resin consumption while maintaining necessary insulation performance.
Solution Approach 2:
The teeth insulating portion is formed with non-uniform thickness distribution, providing thicker insulation only at specific locations where electrical insulation is most critical (on the tooth surfaces facing the rotor), while other areas of the insulator have minimal thickness. This local quality approach ensures insulation reliability is maintained at critical points without unnecessarily increasing resin consumption throughout the entire insulator.
2Ease of operation
If the hole sensor coupling portion is formed on the insulator, then the hole sensor can be coupled, but the insulator requires complex molding processes and increased resin consumption
Solution Approach 1:
The hole sensor coupling portion is merged with the teeth insulating portion rather than being a separate feature on the insulator base. The coupling groove is formed directly on the surface of the teeth insulating portion, combining the insulation function and sensor mounting function into a single integrated structure, thereby simplifying the molding process while maintaining ease of sensor coupling.
Solution Approach 2:
The coupling groove feature is extracted from the insulator base design and relocated to the teeth insulating portion. This extraction allows the insulator base to remain simple in structure while the coupling functionality is provided by the separately formed teeth insulating portion, reducing the complexity requirements for the main insulator mold.
3Device complexity
If the hole sensor coupling portion is formed in a single position on the insulator, then the structure is simplified, but the position to fix the hole sensor is limited
Solution Approach 1:
The design transitions from a fixed coupling position on the insulator base to a dynamic positioning capability where the coupling groove on the teeth insulating portion can be selectively positioned at different locations depending on the specific application requirements. The teeth insulating portion can be configured with coupling grooves at various positions along the teeth, providing adaptability while maintaining structural simplicity.
Solution Approach 2:
The teeth insulating portion serves multiple functions: providing electrical insulation on the tooth surfaces and simultaneously serving as a mounting structure for the hole sensor through the coupling groove. This multi-functionality allows a single component to provide both insulation and positioning capabilities, enabling flexible sensor placement without requiring separate positioning structures.
Data Source
AI summary
The present invention relates to a stator assembly that includes: a stator core having a circular base, a plurality of teeth radially formed along an outer circumference of the base, and at least one coupling bushing formed along an inner circumference of the base; an insulation coating layer formed on an surface of the stator core; and a pair of base insulators coupled to top and bottom portions of the base, respectively.