Stator Insulator Terminal Layout for Easier Coil-End Alignment
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Solution Overview
Problem
The existing motor designs face challenges in aligning the connection ends of the busbar terminal and the coil ends around the stator, and the use of a separate busbar body increases the number of components and assembly processes, making it difficult to manage.
Innovation Solution
The motor design eliminates the need for a busbar body by integrating terminals directly onto an insulator coupled to the stator core, allowing coils to be connected to an external power source without a busbar body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a busbar body is used to connect terminals to the stator, then electrical connection is achieved, but the number of components increases and assembly complexity increases
Solution Approach 1:
The insulator is designed to integrate both mechanical support and electrical connection functions. The terminal is directly coupled to the insulator body, eliminating the need for a separate busbar body. This merging of functions reduces the number of components while maintaining reliable electrical connection between the terminal and stator core.
2Reliability
If a busbar body is used to connect terminals to the stator, then electrical connection is achieved, but the number of assembly processes increases
Solution Approach 1:
The insulator and terminal are designed as an integrated assembly where the terminal is directly coupled to the insulator. This eliminates the need for separate assembly steps to attach a busbar body, reducing the number of assembly processes while ensuring reliable electrical connection.
3Strength
If a busbar body is used, then terminal support is provided, but alignment of terminal and coil ends becomes difficult
Solution Approach 1:
The insulator is pre-positioned on the stator core with the terminal already coupled to it. The terminal part extends toward the coil end, establishing preliminary alignment guidance. This preliminary positioning makes it easier to align the terminal with the coil end during assembly, while the insulator provides the necessary structural support.
4Ease of manufacture
If a busbar body is used, then terminal mounting is enabled, but the structure becomes difficult to manage
Solution Approach 1:
The terminal is directly coupled to the insulator, combining the mounting function into a single integrated component. This reduces the number of separate parts that need to be managed during manufacturing, assembly, and maintenance, while still enabling secure terminal mounting.
Data Source
AI summary
The present invention may provide a motor including a stator core, an insulator coupled to the stator core, and a first terminal and a second terminal which are coupled to the insulator, wherein the stator core includes a yoke and a tooth protruding from the yoke, the insulator includes a body on which the tooth is disposed and a seating part extending from the body and disposed on the yoke, the seating part include a base and first to third partition walls extending from the base, the first terminal is disposed between the first partition wall and the second partition wall, and the second terminal is disposed between the second partition wall and the third partition wall.