Stator Insulator Guide Groove for Crossover-Wire Retention
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Solution Overview
Problem
Conventional rotating electric machines face issues with crossover-wire portions of coils dropping off from uniform circular-arc shaped guide grooves during stator assembly, necessitating complex operations like binding to prevent this.
Innovation Solution
The crossover-wire guide portion of the insulator is designed with guide grooves that guide the crossover-wire portions in a non-circular arc shape, aligning with the stator core's circumferential direction, preventing dropout during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform circular-arc shaped guide grooves are used in the crossover-wire guide portion, then the guide groove structure is simple and easy to manufacture, but the crossover-wire portion of the coil is likely to drop off from the guide groove during stator assembly
Solution Approach 1:
The guide groove is designed with an asymmetric shape where the curvature radius varies along the groove path. Specifically, the curvature radius is smaller at the entrance and exit portions and larger in the intermediate portion, creating a non-uniform circular-arc shape that prevents the crossover-wire from dropping off while maintaining manufacturing feasibility.
Solution Approach 2:
The curvature radius parameter of the guide groove is changed along its length rather than remaining constant. This parameter variation creates a profile that guides the crossover-wire smoothly through the groove while preventing dropout, resolving the contradiction between simple structure and reliable retention.
2Reliability
If complex binding operations are performed to prevent crossover-wire dropout, then the reliability of crossover-wire retention is improved, but the assembly process becomes complicated and time-consuming
Solution Approach 1:
The guide groove structure itself provides the retention function through its specially designed shape, eliminating the need for external binding operations. The groove's varying curvature radius creates natural engagement points that hold the crossover-wire in place during assembly, making the system self-sufficient without additional complex procedures.
3Reliability
If complex binding operations are performed to prevent crossover-wire dropout, then the reliability of crossover-wire retention is improved, but the assembly time increases
Solution Approach 1:
The guide groove is pre-designed with the optimal curvature radius profile during manufacturing, so that the retention function is built-in before assembly begins. This preliminary design eliminates the need for time-consuming binding operations during the actual assembly process, thereby improving productivity while maintaining reliability.
Data Source
AI summary
An insulator includes a teeth cover portion and a crossover-wire guide portion. The crossover-wire guide portion guides a crossover-wire portion of a coil and an introduction crossover-wire portion of an introduction coil into a terminal connection portion. The crossover-wire guide portion has a guide groove that guides the crossover-wire portion and the introduction crossover-wire portion substantially in a core circumferential direction that is a circumferential direction of the stator core. In a state in which the plurality of the split cores are assembled in a ring shape, the guide groove is formed in a shape that does not coincide with a circular arc of a circle having a center corresponding to a ring center of the assembled split cores.