Motor Stator Insulator Guide Surfaces for Winding Space Factor
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Solution Overview
Problem
Conventional motor stators face challenges in maximizing the space factor of windings due to inadequate contact between winding stages, leading to potential coil collapse and reduced efficiency.
Innovation Solution
The motor stator design incorporates an annular yoke with extended portions and guide surfaces on the insulator, allowing the winding to be wound intimately around the wind portion, ensuring proper contact and alignment, thereby increasing the space factor by guiding the winding from one corner to another without interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the winding is wound around the wind portion from the outer-diameter side toward the inner-diameter side, then the space factor of the winding can be increased, but the winding strings may not intimately contact with the wind portion causing coil collapse
Solution Approach 1:
The patent applies preliminary action by providing guide surfaces on the insulator before the winding process. These guide surfaces pre-position and guide the winding strings as they are being wound, ensuring intimate contact with the wind portion from the beginning of the winding process. This prevents coil collapse while allowing the winding to be wound from the outer-diameter side toward the inner-diameter side to maximize space factor.
Solution Approach 2:
The insulator with its guide surfaces acts as an intermediary between the winding and the wind portion. The guide surfaces on the insulator facilitate proper contact and alignment of the winding strings with the wind portion, enabling the winding to be densely packed while maintaining structural integrity.
2Ease of manufacture
If the winding is wound bidirectionally between the flange and the annular member, then the coil can be formed, but the winding strings at subsequent stages may not intimately contact with the first stage winding
Solution Approach 1:
The guide surfaces are provided in advance on the insulator to guide the winding strings during the bidirectional winding process. This preliminary guidance ensures that winding strings at subsequent stages intimately contact with the first stage winding, enabling dense packing and high space factor while maintaining ease of manufacture.
3Productivity
If the first corner is located at the guiding-direction side by the first guide surface relative to the second corner, then the winding can be extended from the second corner to the first corner without interference, but the structure becomes more complex
Solution Approach 1:
The patent applies local quality by providing guide surfaces only at specific locations on the insulator where they are most needed - at the corners and along the paths where winding strings are directed. This localized approach improves winding efficiency without making the entire insulator structure overly complex.
Data Source
AI summary
A wind portion of an insulator includes a side surface at the same side as, in a circumferential direction, a second guide surface which is orthogonal to a holding surface capable of holding a coil and which guides a winding in an inner-diameter direction, and an end surface orthogonal to the side surface. A first corner formed at a boundary between the holding surface and the side surface as viewed in the axial direction of a motor stator is located at a guiding-direction side by a first guide surface relative to a second corner formed at a boundary between the first guide surface and the second guide surface. The winding is extended from the second corner to the first corner.