Motor Stator Insulator Structure for Dual-Winding Coil Isolation
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Solution Overview
Problem
The existing dual winding process in motors often results in insulation issues between the first and second coils, leading to short circuits due to contact between the coils.
Innovation Solution
The use of an insulator with a body portion, guide portion, and blade portion, where the blade portions are tilted in opposite directions to prevent physical connection between the first and second coils, and a protruding portion with grooves to guide the winding of the second coil, ensuring proper insulation and spacing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If dual winding process is performed with first coil and second coil, then motor functionality is achieved, but insulation problem occurs between coils leading to short circuit
Solution Approach 1:
The insulator is divided into multiple functional segments: a body portion that provides base insulation, blade portions that extend to separate the first and second coils, and a guide portion that directs coil winding. This segmentation allows each part to perform its specific insulation function effectively, preventing short circuits between coils while maintaining dual winding capability
Solution Approach 2:
The insulator acts as an intermediary component positioned between the first coil and second coil. The blade portions of the insulator physically separate the two coils, preventing direct contact and short circuits. The guide portion serves as an intermediary structure that guides the second coil during winding while maintaining insulation from the first coil
2Reliability
If blade portions are added to insulator to prevent coil contact, then insulation is improved, but device complexity increases
Solution Approach 1:
Multiple insulation functions are merged into a single insulator component. The body portion, blade portions, and guide portion are integrated into one piece that simultaneously provides base insulation, coil separation, and winding guidance. This merging approach improves reliability without proportionally increasing complexity, as one component performs multiple functions
Solution Approach 2:
The insulator is designed as a multi-functional component: the body portion provides structural support and base insulation, the blade portions prevent coil contact, and the guide portion directs coil winding. This universality allows a single component to address multiple requirements (insulation, separation, guidance) without requiring separate dedicated parts for each function
Data Source
AI summary
A motor has: a housing; a stator disposed inside the housing; a rotor disposed inside the stator; and a shaft coupled to the rotor. The stator has a stator core, an insulator disposed on the stator core, and a coil wound around the insulator. The insulator has: a first body; an inside guide protruding from the inside of the first body; an outside guide protruding from the outside of the first body; a first blade portion disposed to be spaced apart from one side of the first body and to protrude from the outside guide in the radial direction; a second blade portion disposed to be spaced apart from the other side of the first body and to protrude from the outside guide in the radial direction; and a protruding portion extending from one radial side of the first blade portion.