Stator Insulator Radial Thickness Gradient for Residual Stress Relief
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Solution Overview
Problem
Conventional electric motor insulators made of resin material experience inward falling due to residual stress, leading to gaps between the outer peripheral wall and crossover wires, which affects insulating performance and causes frictional rubbing issues during operation.
Innovation Solution
The electric motor design features insulators with an annular outer peripheral wall having a planar inner surface perpendicular to the winding body portions and an arc-shaped outer surface, with increased radial thickness towards the center, and includes groove portions to prevent inward falling and facilitate aligned winding without gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If inward falling preventing ribs are provided at the L-shaped portions, then the inward falling phenomenon is prevented, but the winding operation is hindered and aligned winding cannot be achieved
Solution Approach 1:
The outer peripheral wall portion is divided into multiple radial thickness regions (first, second, and third radial thickness portions) with different thickness characteristics. This segmentation allows the wall to provide reinforcement at critical locations while maintaining smooth surfaces for winding operations, resolving the contradiction between preventing inward falling and enabling easy winding.
Solution Approach 2:
Different regions of the outer peripheral wall portion are given different local qualities through varying radial thickness. The first radial thickness portion has greater thickness for reinforcement, while the second and third portions have reduced thickness to facilitate winding. This local differentiation allows the structure to simultaneously achieve inward falling prevention and ease of winding operation.
2Loss of substance
If the outer peripheral wall portion is made thinner to reduce material usage, then manufacturing cost is reduced, but the inward falling phenomenon worsens over time
Solution Approach 1:
The outer peripheral wall portion employs non-uniform radial thickness distribution, with the first radial thickness portion having greater thickness for structural support and the second and third portions having reduced thickness for material efficiency. This local quality variation optimizes both material usage and inward falling resistance.
Solution Approach 2:
The outer peripheral wall portion exhibits asymmetric thickness distribution around the insulator circumference, with specific regions (first radial thickness portion) having greater thickness than others. This asymmetric design strategically places material where it is most needed to prevent inward falling while minimizing overall material consumption.
Data Source
AI summary
The electric motor includes a rotor and a stator, the stator having a conductive wire wound thereon via a stator core and insulators. The insulators include an annular outer peripheral wall portion with the conductive wire run on an outer periphery side of the peripheral wall portion, a plurality of winding body portions protruding radially from the outer peripheral wall portion, and an inner flange portion. The outer peripheral wall portion on the winding body portion side includes an outer peripheral surface formed in an arc shape. The radial thickness of the outer peripheral wall portion is increasingly greater toward the circumferential center of the winding body portions.