Stator Insulator Step Portion for Winding Interference
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Solution Overview
Problem
Existing stator manufacturing methods face challenges in suppressing interference between the winding machine nozzle and wire layers, particularly when using wires with large diameters, which often requires separate insulators for different diameters and can lead to wire displacement and reduced space factors.
Innovation Solution
A method involving an insulator with a step portion on its winding surface, where the decision to wind on the step portion is determined by specific geometric conditions based on wire diameter and angle, allowing for appropriate layer formation to avoid interference and maintain space factors, regardless of wire diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a wire with a large wire diameter is used to increase motor output and reduce terminal resistance, then the resistance between terminals decreases, but interference between the winding machine nozzle and the winding increases
Solution Approach 1:
The insulator surface is segmented into different levels through the step portion, creating distinct winding zones. This segmentation allows the wire to be properly positioned on the first level while maintaining clearance from the nozzle, resolving the interference issue without requiring smaller wire diameters.
Solution Approach 2:
The step portion introduces a vertical dimension (height difference) to the insulator surface. By winding the wire on the first level surface rather than a flat surface, the patent creates vertical clearance between the wire and nozzle, eliminating interference while maintaining large wire diameter for low resistance.
2Loss of energy
If a wire with a large wire diameter is used, then terminal resistance decreases, but the wire in the first layer is displaced toward the blade tip due to high tension
Solution Approach 1:
The step portion acts as a cushioning structure that absorbs and distributes the tension forces applied to the wire during winding. By providing this pre-designed stress distribution structure, the wire remains stable on the first level surface without being displaced toward the blade tip, even when large diameter wires require high tension for proper winding.
3Manufacturing precision
If an insulator with a groove for engaging the wire is provided to maintain wire space, then wire space factors are maintained, but it becomes necessary to prepare insulators for each different wire diameter
Solution Approach 1:
The step portion design provides universal applicability across different wire diameters. Unlike grooves that must be specifically sized for each wire type, the step portion's geometric features (first level surface and vertical face) work effectively with various wire diameters, allowing a single insulator design to serve multiple wire sizes while maintaining proper wire spacing and positioning.
Solution Approach 2:
The patent changes the insulator geometry from groove-based engagement to step-portion-based positioning. This parameter change in the insulator structure allows it to adapt to different wire diameters through the geometric relationships defined by the step portion, eliminating the need for multiple insulator variants while maintaining wire space factors.
4Power
If the number of turns of windings on teeth is increased to increase motor output, then motor output increases, but the resistance between terminals increases
Solution Approach 1:
The patent changes the wire diameter parameter to resolve the contradiction between increasing turns and maintaining low resistance. By using larger diameter wires, the system can achieve the required current carrying capacity with fewer turns, or maintain the same number of turns with lower resistance, thereby increasing motor output while reducing terminal resistance losses.
Data Source
AI summary
A method includes forming a first wire layer wound on the insulator and a second wire layer wound on the first wire layer by winding the wire on the insulator. If (L1+D)tan(θ/2)cos(θ/2)−A cos(θ/2)>D, the first wire layer is formed by winding the wire on an upper surface of the step portion, where A is B/2+(1+√3/2)D, B is a width of the insulator, D is a wire diameter, θ is an angle formed by the central axes of circumferentially adjacent teeth, L1 is a distance from a central axis of the stator to an end of the upper surface of the step portion on the inner side in the radial direction, and L2 is a distance from the central axis of the stator to an end of the upper surface of the step portion on the outer side in the radial direction.