Stator Insulator Ribs for Brushless Motor Wire Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In electric work machines, the coils on the stator of brushless motors are often misaligned and can cross over each other during winding, reducing the total number of turns and affecting the motor's efficiency and durability.
Innovation Solution
The use of insulators with ribs on the stator core to guide the wire winding process, ensuring that each wire is wound around the teeth in an aligned manner, preventing misalignment and overlap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a wire is wound around the teeth of a stator without additional guiding structures, then the winding process is simpler, but the wire turns become misaligned and may cross each other, reducing the total number of turns
Solution Approach 1:
The patent introduces ribs as intermediary guiding structures on the insulator surface. These ribs act as mediators between the wire and the tooth, providing a physical path that ensures proper wire alignment during winding. The ribs prevent wire crossing and misalignment without complicating the overall manufacturing process, as they can be integrated into the insulator molding.
2Manufacturing precision
If ribs are added to the insulator to guide wire winding, then wire alignment improves and the number of turns increases, but the device complexity increases
Solution Approach 1:
The patent merges the rib guiding structures with the insulator component itself. Rather than adding separate guiding elements, the ribs are formed as integral parts of the insulator during the molding process. This combining approach improves wire alignment while minimizing the increase in device complexity, as the guiding function is achieved through a modification of an existing component rather than adding a new one.
3Productivity
If wire turns are allowed to cross during winding, then the winding process is faster, but the motor efficiency and durability decrease
Solution Approach 1:
The patent implements preliminary action by providing pre-formed rib guides on the insulator before the winding process begins. These ribs预先 establish the correct path for the wire, preventing crossing and misalignment during winding. This preliminary structuring ensures that even at high winding speeds, the wire maintains proper alignment, thus preserving motor efficiency and durability without sacrificing productivity.
Data Source
AI summary
An electric work machine includes a motor in which a wire is wound around each tooth of a stator in an aligned manner. The electric work machine includes a motor including a rotor and a stator. The stator includes a stator core having a first end face and a second end face, and having teeth protruding inwardly, a first insulator covering the first end face, a second insulator covering the second end face, a rib located on at least one of the first insulator or the second insulator, and overlapping the teeth in an axial direction of the teeth, and coils including a wire wound around the teeth via the first insulator and the second insulator and the rib.