Stator Insulator Protrusions for Balanced Winding
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Solution Overview
Problem
Conventional brushless motors with a pull-out structure for coil end portions suffer from unbalanced winding of conductive wires around the stator teeth, leading to unstable resistance and inductance characteristics due to asymmetric coil guide arrangements.
Innovation Solution
The stator design includes an annular core with radially extending teeth, an insulator with annular and protruding portions, and terminal pins positioned on adjacent second protruding portions to ensure balanced winding of conductive wires, preventing unbalanced winding and stabilizing coil characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If coil guides are arranged only on one side in the circumferential direction for teeth, then the device complexity is reduced, but the manufacturing precision deteriorates due to unbalanced winding of conductive wires
Solution Approach 1:
The patent applies asymmetry by providing coil guides on both sides of teeth in the circumferential direction, creating a symmetric arrangement that balances the winding process. This resolves the contradiction by using symmetry (opposite of asymmetry principle) to achieve balanced winding while maintaining simplicity through the uniform placement pattern.
Solution Approach 2:
The patent applies local quality by providing different arrangements of coil guides for different teeth based on their positions. Teeth in certain positions have coil guides on both sides, while other teeth may have coil guides on one side only, allowing optimization of winding balance for each local position while maintaining overall device simplicity.
2Manufacturing precision
If coil guides are provided on both sides for all teeth, then the manufacturing precision is improved by ensuring balanced winding, but the device complexity increases
Solution Approach 1:
The patent provides coil guides on both sides for teeth where winding balance is critical, while potentially using single-sided arrangements for other teeth. This selective approach improves manufacturing precision where needed without unnecessarily increasing device complexity across the entire stator assembly.
3Ease of manufacture
If the conductive wire is wound unbalanced on the left and right in the circumferential direction, then the ease of manufacture is improved by simplifying the coil guide arrangement, but the reliability deteriorates due to unstable resistance and inductance characteristics
Solution Approach 1:
The patent uses symmetric arrangement of coil guides on both sides of teeth to ensure balanced winding of conductive wires. This symmetry in the arrangement maintains ease of manufacture through uniform placement while ensuring reliable and stable resistance and inductance characteristics through balanced winding tension and geometry.
Solution Approach 2:
The patent creates homogeneous winding conditions by providing coil guides on both sides of teeth, ensuring that the conductive wire experiences uniform support and tension during winding. This homogeneity in the winding environment stabilizes the electrical characteristics while maintaining manufacturing simplicity through consistent placement patterns.
Data Source
AI summary
A stator for use in a motor includes a stator core, an insulator, a coil, and a terminal pin. The stator core includes a core back having an annular shape and teeth. The insulator covers at least a portion of the stator core. The coil is defined by a conductive wire wound around the teeth via the insulator. The terminal pin extends axially upward from an upper surface of the insulator and is connected to an end portion of the conductive wire. The insulator includes an annular portion, first protruding portions, and second protruding portions. The annular portion covers at least a portion of the core back and is centered on the central axis. The plurality of first protruding portions cover at least a portion of each of the teeth and protrude radially outward from the annular portion.