Stator Assembly Magmate Holder and Sensor Cover Design
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Solution Overview
Problem
The existing stator assembly designs require extensive resin molding and complex manufacturing processes, leading to increased costs due to the use of insulators covering the entire stator core and enlarged sensor covers for terminal connections.
Innovation Solution
A stator assembly with a magmate holder and sensor cover that eliminates the need for insulators covering the entire stator core, using a powder coating for insulation and a simplified structure with a magmate holder and sensor cover joined via a bolt and hooks, reducing resin usage and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulators are used to cover the entire stator core, then insulation reliability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent removes the insulator component from the stator assembly, extracting the insulation function from a separate mechanical component and replacing it with a surface treatment (powder coating) applied directly to the stator core. This eliminates the need for separate insulator molding and assembly steps, reducing manufacturing complexity while maintaining insulation reliability through the coating layer.
2Reliability
If insulators cover the entire stator core, then insulation is ensured, but resin molding amount increases
Solution Approach 1:
The patent eliminates the resin insulator component entirely, extracting the insulation function from a material-intensive component and replacing it with a thin powder coating layer. This dramatically reduces the amount of resin molding material required while maintaining the necessary insulation properties through the coating's dielectric characteristics.
3Ease of operation
If tap terminals are formed inside the upper insulator, then connectivity is achieved, but sensor cover size increases
Solution Approach 1:
The patent removes the tap terminals from the insulator structure and relocates them to the stator core surface. This extraction allows the sensor cover to be significantly reduced in size since it no longer needs to accommodate large internal terminal structures, while connectivity is maintained through the repositioned terminals that can be accessed more compactly.
4Ease of manufacture
If the stator core surface is insulated by powder coating, then manufacturing cost is reduced, but insulation coverage is limited to surface only
Solution Approach 1:
The patent changes the insulation approach from a thick volumetric insulator to a thin surface coating layer. By transforming the insulation from a bulk material problem to a surface treatment problem, the manufacturing cost is reduced through simpler application processes and material savings, while the coating's dielectric properties provide sufficient insulation coverage for the application requirements.
Data Source
AI summary
Disclosed therein is a stator assembly, which includes a circular base part and a stator core having a plurality of teeth radially formed on an outer face of the base part and respectively having a tooth end portion. The stator assembly further includes: a magmate holder including a base plate, at least one inner leg and at least one outer leg formed at a lower portion of the base plate, and a power connector part formed on an upper portion of the base plate and having a joining projection formed at one side thereof; and a sensor cover including a body part and a hook formed on a lower portion of the body part and being joined with the joining projection.