Stator Insulator Guide Tabs for Coil Connection
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Solution Overview
Problem
Current motor manufacturing processes for parallel connection of stator windings are complex, costly, and unreliable due to the need for separate busbar assemblies and numerous manual operations, which increase manufacturing time and material costs while reducing connection reliability.
Innovation Solution
A stator insulator with guide tabs and grooves that allows three-phase coils and neutral coils to be mounted and connected along the outer circumferential surface, eliminating the need for separate busbar assemblies and simplifying the connection process by guiding coils through a circumferential arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate busbar assembly is used for parallel connection, then connection reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The insulator integrates both insulation and parallel connection functions by incorporating connection ribs with conductive portions directly on the insulator body, eliminating the need for separate busbar assemblies while maintaining connection reliability through the unified structure
Solution Approach 2:
The insulator serves multiple functions simultaneously: electrical insulation between coils, structural support for the stator, and parallel connection conduit through its integrated connection ribs that guide and connect coil ends, reducing the total number of components required
2Manufacturing precision
If manual processes are used to arrange lead wire and neutral wire, then connection precision is improved, but manufacturing time and labor cost increase
Solution Approach 1:
The connection ribs are pre-formed on the insulator with predetermined positions and orientations, allowing coils to be directly connected to predefined locations without requiring manual arrangement of lead and neutral wires during assembly
Solution Approach 2:
The insulator's connection ribs automatically guide and position the coil ends through their integrated groove structures, enabling the system to self-align connections without manual intervention while maintaining precise connection positioning
3Ease of manufacture
If direct crimping type process is used, then manufacturing cost is reduced, but connection reliability and manufacturing time worsen due to numerous manual processes
Solution Approach 1:
The patent replaces manual mechanical crimping processes with an integrated insulator structure that provides mechanical guidance and alignment through connection ribs, allowing for more reliable connections while maintaining cost-effectiveness through reduced labor requirements
4Ease of operation
If busbar assembly is used for parallel connection, then connection process is simplified, but material cost and device complexity increase
Solution Approach 1:
The insulator combines insulation material with integrated connection ribs that serve as built-in busbar structures, eliminating the need for separate busbar materials while maintaining the simplified connection process through the unified design
Data Source
AI summary
An insulator is configured to couple to a top portion of a stator core and includes: a main body that has a ring shape; a plurality of insulating teeth that protrude toward a center portion of the main body and that are configured to couple to a plurality of teeth of the stator core, respectively; and a plurality of guide tabs that protrude from an outer circumferential surface of the main body at positions corresponding to the plurality of insulating teeth. The plurality of guide tabs are configured to guide (i) phase coils that are wound around the plurality of insulating teeth and (ii) neutral coils along the outer circumferential surface in a circumferential direction. Each of the plurality of guide tabs defines a plurality of guide grooves, each of the plurality of guide grooves being configured to seat at least one of the phase coils or the neutral coils.