External Rotor Motor Stator with Patch Board Fastening
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional stators for external rotor motors face issues such as unstable connections between the stator winding and power wire, risk of solder joint breakage, and disorderly distribution leading to component damage and reduced operational life.
Innovation Solution
A stator design featuring a stator core with teeth and slots, a patch board with a fastening device that securely fixes the weld-connecting portion between the stator winding and power wire, ensuring orderly distribution and preventing contact with other motor components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to connect the stator winding head to the power wire, then electrical connection is achieved, but the solder joint is easy to be broken and connection is unstable
Solution Approach 1:
The invention divides the connection structure into multiple functional parts: the welding area for electrical connection, the insulating area with injected insulators for protection, and the fastening area with the fastening device for mechanical securing. This segmentation allows each part to perform its specific function optimally, preventing the solder joint from bearing mechanical stress that would cause breakage.
Solution Approach 2:
The insulators act as an intermediary element between the welded connection and the external environment. By injecting insulators into the insulating cavity that surrounds the welding area, the patent provides both electrical insulation and mechanical protection to the vulnerable solder joint, preventing direct exposure to stresses that would cause failure.
2Device complexity
If no fixing device is provided at the solder joint, then the structure is simple, but the stator winding head and power wire are disorderly distributed and may contact with other components
Solution Approach 1:
The end plate serves multiple functions: it provides structural support for the stator core, contains the insulating material, and incorporates the fastening device to secure the electrical connections. This multi-functionality reduces the need for separate fixing components while maintaining orderly component distribution and preventing contact with other motor parts.
Solution Approach 2:
The invention utilizes the third dimension by injecting insulators into the insulating cavity and positioning components in different spatial layers. The fastening device extends from the end plate into the insulating cavity to secure the power wire, creating a three-dimensional arrangement that organizes components systematically and prevents disordered distribution.
3Reliability
If insulators are injected and end plates are formed, then connection protection is improved, but the device complexity increases
Solution Approach 1:
The patent merges the insulating function and the structural support function into a single integrated end plate assembly. The end plate is formed as one piece that incorporates the insulating cavity, and insulators are injected into this pre-formed cavity. This combining of functions reduces the number of separate components needed while providing comprehensive protection for the electrical connections.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances the stability and operational life of the motor by improving the connection between the stator winding and power wire, maintaining a compact and reasonable structure with low production costs.
Implementation Method 1
stator winding is received in the slot and wrapped around the teeth of the stator core
Data Source
AI summary
A stator for an external rotor motor, containing at least a stator core (1) having multiple teeth (4) and a shaft (3), a stator winding (2), multiple slots (5), a pair of end plates (6), a patch board (7) having a first through hole (8), a power wire (11), and a fastening device (9). The shaft (3) is disposed at the center of the stator core (1). The slot (5) is formed between adjacent teeth (4) of the stator core (1). The stator winding (2) is received in the slot (5) and wrapped around the teeth (4). The patch board (7) is disposed above one of the end plates (6). The shaft (3) passes through the first through hole (8) of the patch board (7). The fastening device (9) is disposed at the top of the patch board (7) and operates to fix the weld-connecting portion (10).