Stator Insulator Crossover-Wire Guide for Coil Shape Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional rotating electric machines experience deformation of the coil winding shape during assembly due to slackness in the crossover-wire portion when drawing coils from the teeth cover portion to the outer side of the core radial direction.
Innovation Solution
An insulator with a crossover-wire guide portion featuring guide walls, a drawing groove, a drawing path, and a crossover-wire support portion is used to separate and guide crossover-wire portions of different phases, preventing deformation by supporting the crossover-wire portion and directing it into the drawing path, thus maintaining the winding shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the crossover-wire portion is simply bent along a guide groove without additional support structures, then the device complexity is reduced, but the coil winding shape deforms during assembly due to slackness
Solution Approach 1:
The crossover-wire guide portion is segmented into multiple functional elements: guide walls that separate different phases, a drawing groove for initial positioning, a drawing path for directional guidance, and a support portion for stabilization. This segmentation allows each element to perform its specific function while collectively preventing coil deformation without excessive complexity
Solution Approach 2:
The drawing path acts as an intermediary structure between the drawing groove and the final coil positioning area. It provides a controlled transition path that guides the crossover-wire portion through the assembly process, preventing slackness-induced deformation while maintaining a relatively simple overall structure
2Manufacturing precision
If the crossover-wire portion is supported and directed through multiple structures (guide walls, drawing path, support portion), then the coil winding shape is maintained, but the device complexity increases
Solution Approach 1:
Multiple functional elements (guide walls, drawing groove, drawing path, and support portion) are merged into a single integrated crossover-wire guide portion that is formed as one piece with the teeth cover portion. This merging maintains manufacturing precision while avoiding the complexity of multiple separate components requiring assembly
Solution Approach 2:
The teeth cover portion serves multiple functions: it provides structural support for the coil, acts as an insulator, and integrates the crossover-wire guide portion with its multiple sub-functions (guiding, separating, and supporting). This multi-functionality reduces overall device complexity while maintaining coil winding precision
3Manufacturing precision
If guide walls are added to separate crossover-wire portions of different phases, then phase separation and alignment are improved, but the device complexity increases
Solution Approach 1:
Guide walls are added only in specific locations where phase separation is needed, rather than throughout the entire structure. The guide walls create localized separation zones for different phases while maintaining a relatively simple overall guide structure, thus improving alignment precision without excessive complexity increase
Data Source
AI summary
An insulator according to an embodiment includes a teeth cover portion and a crossover-wire guide portion. The crossover-wire guide portion includes a plurality of guide walls, a drawing groove, a drawing path, and a crossover-wire support portion. The plurality of the guide walls separate the crossover-wire portions of the coils and are capable of guiding the crossover-wire portions in the core circumferential direction. The drawing groove penetrates through all of the plurality of the guide walls in the core radial direction. The drawing path is disposed at a position away from the drawing groove in the core circumferential direction. The crossover-wire support portion changes a direction of the crossover-wire portion of the coil drawn out from the drawing groove, to be directed to the drawing path, and supports the crossover-wire portion.