Stator Insulator Coil Guide Grooves for Variable Coil Diameters
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Solution Overview
Problem
Conventional stator configurations require mold reforming for insulators to accommodate different coil diameters, leading to increased costs and inefficiencies in motor performance.
Innovation Solution
A stator segment with a coil guide groove system comprising a first and second guide groove, allowing for oblique winding and reliable locking of coils, enabling regular winding regardless of coil diameter and direction, thus improving design freedom and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the width of the holding groove or the step/slope configuration is changed to accommodate different coil diameters, then the coil can be properly held and wound, but the mold must be reformed increasing manufacturing costs
Solution Approach 1:
The insulator is designed with a universal coil guide groove structure that can accommodate coils of different diameters without requiring mold reforming. The groove configuration with specific angle ranges (30-60 degrees for the first groove, 10-30 degrees for the second groove) allows a single insulator design to serve multiple coil diameter specifications, eliminating the need for custom molds for each coil variant.
2Device complexity
If a conventional holding groove structure is used, then the insulator structure is simple, but the coil cannot be regularly wound when diameter varies
Solution Approach 1:
The insulator features localized guide grooves with specific geometric properties (angles, depths, and positions) that are optimized for guiding coils during winding. The first guide groove has a steeper angle (30-60 degrees) for initial coil entry, while the second guide groove has a shallower angle (10-30 degrees) for final positioning, creating localized functional zones that ensure regular winding without complicating the overall insulator structure.
3Loss of energy
If the coil space factor is increased to improve motor efficiency, then the loss from current flow is reduced, but the insulator design becomes more constrained
Solution Approach 1:
The guide groove structure is designed to dynamically adapt to coils of varying diameters through its geometric configuration. The angled surfaces and groove dimensions allow the structure to accommodate different coil sizes while maintaining optimal coil positioning and spacing, enabling increased coil space factor and improved energy efficiency without imposing rigid design constraints.
Data Source
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AI summary
An insulator 5 includes a part 50 to be wound with a coil 7; a first flange 51; and a second flange 52. The first flange 51 is formed at the side of the part 50 closer to a core segment 41, and includes a coil guide groove 53 that guides the coil 7 to the part 50. The second flange 52 is formed at the side of the part 50 closer to a distal end of a teeth 42. The coil guide groove 53 includes a first guide groove 53a and a second guide groove 53b symmetrical with respect to a radial plane. Each of the first and second guide grooves 53a and 53b extends at an acute angle θ from an inner surface 51a of the first flange 51.