One-piece stator insulator for electric motor coil positioning
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Solution Overview
Problem
Conventional stator cores in electric motors face challenges in securely positioning and preventing the displacement of insulators, which are essential for electrical insulation and maintaining coil integrity.
Innovation Solution
The design incorporates seamless one-piece insulators with coil side-insulation and coil end-insulation parts that are integrally coupled, arranged to overlap and connected by additional parts, ensuring secure positioning and effective electrical insulation between coil ends and sides, thereby preventing displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional separate insulators are used for coil side and coil end insulation, then manufacturing flexibility is maintained, but device complexity increases and positioning reliability deteriorates
Solution Approach 1:
The patent merges the coil side insulator and coil end insulator into a single integrated insulator structure. The coil side insulator portion and coil end insulator portion are formed as one piece, eliminating the need for separate components and their assembly, thereby reducing device complexity while improving positioning reliability through integrated design
Solution Approach 2:
The integrated insulator serves multiple functions simultaneously: it provides electrical insulation for the coil side, insulation for the coil end, and structural support for positioning. This multi-functional design reduces the number of components needed while maintaining comprehensive insulation coverage
2Productivity
If seamless one-piece insulators are used, then manufacturing precision and productivity improve, but ease of repair deteriorates
Solution Approach 1:
While the insulator is manufactured as a seamless one-piece structure for production efficiency, the design inherently segments the insulation functions into distinct portions (coil side and coil end portions) that can be independently analyzed and replaced if needed, balancing manufacturing efficiency with maintenance flexibility
3Reliability
If coil end-insulation parts of adjacent insulators overlap and are connected, then insulation reliability improves, but device complexity increases
Solution Approach 1:
The overlapping coil end-insulation parts of adjacent insulators are connected through integration into the seamless one-piece structure, merging what would otherwise be separate connection components into the insulator body itself, thereby improving insulation reliability without proportionally increasing device complexity
Data Source
AI summary
A stator capable of preventing the displacement of insulators and securely positioning the insulators at given positions. A stator includes a stator core formed with slots; a coil wound around the stator core, the coil comprising a coil side and a coil end, the coil end arranged outside the slot; and insulators provided in the slots. Each insulator includes a coil side-insulation part arranged between wall surfaces of a slot and a first coil side and electrically insulating the wall surfaces from the first coil side; and a coil end-insulation part formed in one piece with the coil side-insulation part and arranged outside the first slot. The coil end-insulation part is arranged between a first coil end and a second coil end and electrically insulates the first coil end from the second coil end.