Stator Insulator Notch and Cover Structure for Crossover Wire Insulation
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Solution Overview
Problem
Existing motors for electric compressors in eco-friendly vehicles face issues with crossover wires projecting outward from the outer wall part of the electrical insulator assembly, leading to reduced insulation distance and potential contact with adjacent parts.
Innovation Solution
The motor design incorporates notches in the outer wall part of the electrical insulator assembly to guide extensions, along with a removable cover that restricts axial movement and enhances insulation, and uses insulation tubes and members to cover winding start wires and neutral points, preventing outward projection and ensuring adequate insulation distance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the crossover wire is drawn back from the outside to the inside of the outer wall part via a notch, then the wire can be connected between winding parts, but the wire may project outward of the outer wall part causing reduced insulation distance or contact with adjacent parts
Solution Approach 1:
A cover member is introduced as an intermediary component between the outer wall part and the crossover wire. The cover member includes a recess that receives the crossover wire and an outer peripheral surface that contacts the outer wall part, preventing the wire from projecting outward while maintaining proper routing through the notches.
Solution Approach 2:
The solution moves from a two-dimensional planar routing problem to a three-dimensional spatial solution by adding the cover member that extends in the axial direction. The recess in the cover member provides a new spatial dimension for accommodating the wire, allowing it to be contained without projecting outward.
2Reliability
If a projection is provided on the outer wall part to suppress outward projection of the crossover wire, then insulation distance is improved, but the structure becomes more complex
Solution Approach 1:
The insulator assembly is segmented into distinct functional components: the outer wall part with notches for wire routing, and a separate cover member that provides the containment function. This segmentation allows each component to be optimized independently - the outer wall part maintains its simple notch structure while the cover member provides the necessary projection suppression.
Solution Approach 2:
The cover member acts as an intermediary between the outer wall part and the crossover wire, providing the containment function without modifying the outer wall part itself. This maintains the simplicity of the original insulator assembly while adding the necessary functionality through a separate, removable component.
3Power
If the motor uses high-pressure specifications with increased power supply voltage, then motor performance is improved, but the risk of electrical contact and insulation failure increases
Solution Approach 1:
The cover member is installed beforehand to create a protective barrier that cushions against potential electrical contact. The recess receives the crossover wire and the outer peripheral surface maintains insulation distance from adjacent parts, preventing harmful electrical contact before it can occur, especially important under high-voltage operating conditions.
Solution Approach 2:
The cover member is made from resin or insulating material that provides adequate protection for the intended service life of the motor. While the cover itself may be a simpler, less expensive component, it provides critical protection against insulation failure in the high-voltage environment, ensuring reliable operation throughout the motor's operational lifespan.
Data Source
AI summary
A motor includes a rotor and a stator, the stator having a stator core and an electrical insulator assembly at each end of the stator core. The electrical insulator assemblies each have an outer wall part extending in a circumferential direction and facing a yoke of the stator core and a plurality of extending parts extending radially inward from the outer wall part and facing teeth of the stator core. The outer wall part has a radial thickness and includes a plurality of radial notches for guiding extensions of the stator winding between an inner peripheral surface and an outer peripheral surface of the outer wall part. The outer peripheral surface of the outer wall part adjacent to the notches is configured such that the radial thickness of the outer wall part gradually decreases toward the notch along a circumferential direction of the yoke.