Stator Insulator Yarn Securing Passage Design
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Solution Overview
Problem
The existing methods for securing lead wires in motors are complex and prone to causing insulation damage during the tying process, leading to defective products and reduced production efficiency.
Innovation Solution
A stator design with a cylindrical core, radially extending teeth, and an insulator with passage portions, grooves, and notches that allow yarn to be securely passed through without direct contact with lead wires or coil windings, reducing misalignment and hindrance to rotor rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lead wires are tied and secured with a yarn using a needle to pass through holes or hooks in the insulator, then the lead wires are secured relative to the insulator, but the needle may accidentally puncture the lead wires or coil windings, causing insulation fracture and defective products
Solution Approach 1:
The patent introduces a yarn as an intermediary element that secures the lead wires without requiring a needle to penetrate the insulation. The yarn passes through a hole in the insulator and wraps around the lead wires, providing securing function while eliminating the puncture risk associated with needle-based methods.
Solution Approach 2:
The patent extracts the needle from the tying process entirely, replacing it with a hole-through method where the yarn is directly inserted through a pre-formed hole in the insulator. This removes the harmful element (needle) that caused insulation damage while maintaining the securing function.
2Reliability
If the yarn is engaged in a hook-shaped portion or passed through a hole in the insulator using a needle, then the tying operation can be performed, but the operation requires significant effort, time, and attention, reducing production efficiency
Solution Approach 1:
The patent incorporates a hole in the insulator during the insulator manufacturing process itself, rather than requiring subsequent manual operations to create or engage with hooks. This preliminary preparation of the tying path significantly reduces the complexity and time required for the actual tying operation.
Solution Approach 2:
The yarn serves as a simple intermediary that can be easily threaded through the pre-formed hole and wrapped around the lead wires, providing a straightforward tying mechanism that does not require complex needle manipulation or hook engagement, thereby improving production efficiency.
3Reliability
If the passage portion is formed in the teeth cover portion, then the yarn can be passed through without direct contact with coil windings, but the structure requires additional features (grooves and notches) to prevent rotor hindrance
Solution Approach 1:
The passage portion formed in the teeth cover portion acts as an intermediary channel that guides the yarn away from direct contact with the coil windings. This structural feature protects the insulation by providing a dedicated path for the yarn that does not intersect with the coil windings, even though it adds some structural complexity.
Solution Approach 2:
The insulator is segmented into multiple functional regions: the outer wall, the teeth cover portions with passage portions, and the inner walls with grooves and notches. This segmentation allows each region to perform its specific function (protection, guidance, constraint) while collectively solving the overall problem of securing lead wires without hindering rotor rotation.
Data Source
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AI summary
A stator (50) includes a core (10), an insulator (20), a plurality of coil windings (30), outgoing lines (40), and a yarn (S) securing the outgoing lines (40) to the insulator (20). The insulator (20) is placed on an end surface (13) of the core (10) and has an outer wall (21), a plurality of teeth cover portions (23), and a plurality of inner walls (22). The outer wall (21) surrounds a central axis C and erected in such a way as to upwardly extend from the end surface (13). The teeth cover portions (23) radially inwardly extend from the outer wall (21) toward the central axis C. The inner walls (22) are each erected at an end portion of each of the teeth cover portions (23). The coil windings (30) are placed between the outer wall (21) and the inner wall (22). A passage portion (24) radially extending is formed in at least one of the teeth cover portions (23). The passage portion (24) passes the yarn (S).