Electric Motor Stator Insulator for Winding Stability
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Solution Overview
Problem
In 6-slot concentrated winding stators, the increased length of unwound windings leads to poor workability and a high likelihood of power wires contacting tooth winding portions of other phases, causing assembly challenges and potential electrical issues.
Innovation Solution
The electric motor stator design features a stator core with teeth and slots, where windings are wound around opposed teeth with a crossover wire held between tooth winding portions and an insulator, preventing radial displacement and using wiring separators to maintain distance between power and neutral wires, thus stabilizing the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the winding length increases to connect same phases positioned 180 degrees opposite, then the wiring complexity increases, but the workability deteriorates and the likelihood of contact with other phases increases
Solution Approach 1:
The patent introduces an insulator as an intermediary component with a support portion that supports the power wire at the bottom of the slot. This mediator prevents the power wire from contacting tooth winding portions of other phases while maintaining proper wiring connectivity between phases positioned 180 degrees opposite, thereby resolving the contradiction between reliability and ease of operation
Solution Approach 2:
The insulator is pre-positioned in the slot with its support portion prepared to hold the power wire. This preliminary arrangement ensures that when the power wire is routed through the stator, it is immediately supported and positioned correctly, preventing contact with other phases before the winding process is complete, thus improving both reliability and workability
2Reliability
If insulating tubes or sleeves are used to insulate crossover wires, then insulation is provided, but the device complexity increases
Solution Approach 1:
The patent merges the insulation function and support function into a single integrated insulator component. The insulator's support portion provides both mechanical support for the power wire and electrical insulation, eliminating the need for separate insulating tubes or sleeves, thereby reducing device complexity while maintaining reliability
Solution Approach 2:
The insulator serves multiple functions simultaneously: it provides electrical insulation for the power wire, mechanical support to prevent contact with other phases, and structural integration with the stator core. This multi-functionality eliminates the need for additional dedicated insulation components, reducing overall device complexity
Data Source
AI summary
An electric motor stator has a stator core and a plurality of windings wound around teeth of the stator core. Each of the windings has two tooth winding portions with a crossover wire extending therebetween. Each of the windings starts from a neutral wire and winds around a first tooth to form a first tooth winding portion and then winds around an opposed tooth to form a second tooth winding portion with the crossover wire extending as a power wire. Thus, the second tooth winding portion is started from the power wire. A terminal end of the second tooth winding portion is drawn out and connected to the neutral wire. The stator core has an insulator having support portions for preventing the tooth winding portions from falling outwards. The power wire is held between the tooth winding portion and a slot bottom so as to be fixed.