Motor Stator Insulator Groove Structure for Variable Coil Diameters
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Solution Overview
Problem
Conventional motor insulators require mold reforming for different coil diameters, leading to increased costs and inefficiencies in achieving regularly wound coils, as existing configurations necessitate changes in groove width or slope angles.
Innovation Solution
The insulator design features a coil guide groove with a first groove extending at an acute angle and a second groove with a smaller acute angle, allowing the coil to obliquely enter and be regularly wound, along with a coil lock to prevent deformation and movement, facilitating reliable locking and regular winding across varying coil diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the width of the holding groove or the angle of the slope is changed to accommodate different coil diameters, then the coil can be properly wound, but the mold must be reformed, increasing manufacturing costs and reducing efficiency
Solution Approach 1:
The insulator is designed with a universal coil guide groove structure that can accommodate coils of different diameters without requiring mold changes. The groove's geometric configuration (acute angle extension followed by smaller acute angle section) allows it to function across multiple coil size specifications, making the insulator multi-functional and eliminating the need for custom molds for each coil diameter.
Solution Approach 2:
The coil guide groove utilizes angular parameter variations (first acute angle θ, then smaller acute angle θ1) to create a geometry that adapts to different coil diameters. By changing the angular parameters rather than the mold itself, the same mold can produce insulators that work with various coil sizes, resolving the contradiction between adaptability and manufacturing simplicity.
2Ease of manufacture
If conventional insulator configurations are used, then manufacturing is simplified, but regular winding of coils with different diameters cannot be achieved
Solution Approach 1:
The coil guide groove is pre-formed on the insulator with specific angular configurations before the coil winding process. This preliminary geometric preparation ensures that when the coil is wound, it automatically follows the desired regular path regardless of coil diameter, achieving both manufacturing simplicity and winding precision simultaneously.
Solution Approach 2:
The coil guide groove acts as an intermediary element between the insulator body and the coil. It mediates the interaction by providing a geometric pathway that guides the coil into proper alignment and regular winding, ensuring precise winding results while maintaining simple insulator manufacturing processes.
3Device complexity
If the coil guide groove uses a single acute angle configuration, then the structure is simpler, but the coil cannot be properly guided for regular winding across different diameters
Solution Approach 1:
The coil guide groove is segmented into two distinct angular sections: a first acute angle θ section and a second smaller acute angle θ1 section. This segmentation allows each section to perform a specific function in guiding different portions of the coil, enabling the structure to accommodate a wider range of coil diameters while maintaining reasonable structural complexity.
Solution Approach 2:
The solution transitions from a single-angle (one-dimensional parameter) approach to a multi-angle (multi-dimensional parameter) approach. By introducing angular variation along the groove length, the structure gains additional degrees of freedom to accommodate different coil diameters, effectively using dimensional change to expand adaptability without excessive complexity.
Data Source
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AI summary
An insulator 5 includes a part 50 to be wound with a coil 7, a first flange 51, and a second flange 52. The first flange 51 is formed at the side of the part 50 closer to a core segment 41, and includes a coil guide groove 53 that guides the coil 7 to the part 50. The second flange 52 is formed at the side closer to a distal end of a tooth 42. The coil guide groove 53 includes a first groove 53a extending at an acute angle θ from an inner surface 51a of the first flange 51.