Motor Stator Insulator Guide Grooves for Winding Load Reduction
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Solution Overview
Problem
Conventional motor stator insulators apply uneven loads to windings due to the linear and oblique winding patterns, leading to increased stress and inefficiencies in the winding process.
Innovation Solution
The insulator features intermittently provided guide grooves on its surfaces, oriented in the winding direction and arranged radially, with consistent offset patterns to guide the winding smoothly across boundaries, reducing load application and allowing for more efficient winding alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If guide grooves are formed continuously across all wind surfaces including the fourth wind surface, then the winding can be guided linearly throughout, but the winding must be bent at boundaries causing load application
Solution Approach 1:
The guide grooves are segmented and provided only on specific wind surfaces (first to third wind surfaces) rather than continuously across all surfaces. This segmentation allows the winding to be guided linearly on most surfaces while avoiding the need for bending on the fourth wind surface, thereby reducing load application on the winding.
Solution Approach 2:
Instead of providing guide grooves on all surfaces including the fourth wind surface (conventional approach), the invention inverts the approach by deliberately omitting guide grooves from the fourth wind surface. This inversion prevents the winding bending issue at boundaries while maintaining adequate guidance on other surfaces.
2Ease of operation
If guide grooves are provided on the fourth wind surface, then winding guidance is continuous, but the winding pattern becomes oblique causing row shifting
Solution Approach 1:
Guide grooves are segmented and provided only on the first to third wind surfaces, creating distinct linear guidance zones. This segmentation ensures that the winding follows a precise linear path on these surfaces without oblique deviations, maintaining manufacturing precision while providing adequate guidance functionality.
3Device complexity
If guide grooves are provided intermittently only at boundaries, then winding guidance is provided where needed, but the winding lacks continuous guidance across wind surfaces
Solution Approach 1:
The guide grooves are segmented and strategically positioned on the first to third wind surfaces where linear guidance is most needed. This segmented approach provides guidance functionality without requiring continuous grooves across all surfaces, reducing device complexity while maintaining adequate winding guidance.
Solution Approach 2:
Guide grooves are provided locally on specific wind surfaces (first to third) rather than uniformly across all surfaces. This local quality approach ensures that guidance is provided precisely where the winding needs linear direction, while avoiding unnecessary grooves on the fourth wind surface where they would cause oblique winding issues.
Data Source
AI summary
Guide portions that guide a winding include a plurality of guide grooves which is provided at each boundary between adjacent wind surfaces, and which is extended in a winding direction of the winding. The plurality of guide grooves is arranged side by side in a radial direction of a stator at an equal pitch. The guide groove provided at an arbitrary boundary among the boundaries is offset in the radial direction relative to the guide groove provided at the adjacent boundary at the opposite side to the winding direction with reference to an orthogonal direction to the radial direction of the motor stator. Respective offset directions and offset amounts of the guide grooves are consistent.