Stator Insulator Guide Structure for Smooth Insulating Sheet Assembly
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Solution Overview
Problem
The assembly of insulators and insertion of insulating sheets in motors is challenging due to difficulties in achieving uniform positioning and interference from protrusions, leading to hooking phenomena and assembly issues.
Innovation Solution
The motor design includes a stator with insulators featuring a guide protrusion having an inclined surface that guides the insulating sheet insertion, minimizing hooking and facilitating easier assembly by using a second insulator that couples with the first along an inclined surface, with specific inclination angles and steps to enhance assemblability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If insulating sheets are inserted between coils after stator assembly, then the stator can be assembled with housing, but uniform positioning of insulating sheets becomes difficult and hooking phenomena occur
Solution Approach 1:
The protrusion is pre-formed on the insulator before coil winding, creating a guide structure that directs the insulating sheet into proper position during assembly. This preliminary structural preparation ensures uniform positioning is achieved automatically during the assembly process rather than requiring post-assembly adjustment.
Solution Approach 2:
The protrusion acts as an intermediary element between the insulator and the insulating sheet. It provides a mechanical guide structure that mediates the insertion process, directing the insulating sheet to the correct position and preventing hooking phenomena by controlling the interaction between these components.
2Strength
If protrusions are used to fix coils to insulators, then coil fixation is achieved, but insertion of insulating sheets is interfered with causing hooking phenomena
Solution Approach 1:
The protrusion is designed with differentiated local qualities: the upper portion maintains a shape that provides strong coil fixation, while the lower portion incorporates an inclined surface that creates a smooth guide for insulating sheet insertion. This local differentiation allows the same structure to fulfill both fixation and guidance functions without interference.
Solution Approach 2:
Instead of designing the protrusion to maximize fixation strength alone, the design inverts the approach by incorporating an inclined surface that prioritizes smooth insulating sheet insertion. The fixation function is maintained through the upper portion geometry while the insertion path is optimized by the inclined lower portion, reversing the traditional priority.
Data Source
AI summary
The present invention provides a motor including a shaft, a rotor coupled to the shaft, and a stator disposed outside the rotor, wherein the stator includes a stator core, insulators disposed on the stator core, coils disposed on the insulators, and insulating members disposed between the insulators in a circumferential direction, the insulator includes a body on which the coil is disposed and a guide extending from one side of the body, the guide includes a protrusion protruding from an inner circumferential surface toward a center of the stator, and a lower portion of the protrusion includes a first inclined surface.