Stator Projections with Segmented Guide Paths for Wiring
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Solution Overview
Problem
In inner-rotor type electric motors, transition wirings often come into contact with each other due to their configuration, leading to potential insulation breakdowns and conductive states, especially under vibration, as they are typically insulated wires wound around stator cores and must be routed around the outer circumference of the stator.
Innovation Solution
A stator design featuring projections with guide paths that individually space and direct transition wirings, preventing contact by maintaining them in parallel and increasing in length towards the stator core, thereby ensuring they remain straight and avoid intersections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If transition wirings are routed around the outer circumference of the stator to connect coils, then wiring between confronting or mating coils is achieved, but the transition wirings come into contact with each other causing insulation breakdown
Solution Approach 1:
The projection is divided into multiple guide paths that separately route different transition wirings. Each guide path acts as an independent channel, preventing the wirings from contacting each other while maintaining their connectivity function. This segmentation of the routing space directly resolves the contradiction by allowing wiring connectivity through structured paths while preventing insulation breakdown through physical separation.
Solution Approach 2:
The projection with guide paths serves as an intermediary structure between the coils and the housing/rotor. It provides a controlled interface that guides the transition wirings in predetermined paths, preventing direct contact between wirings and between wirings and other components. This intermediary structure enables wiring connectivity while ensuring insulation integrity through controlled routing.
2Device complexity
If multiple transition wirings are retained on the same projection to connect three-phase coils, then all transition wirings are consolidated in one location, but the wirings intersect and contact each other under vibration
Solution Approach 1:
The projection surface is segmented into multiple guide paths, each dedicated to routing specific transition wirings. This segmentation consolidates the wirings on a single projection structure while preventing their contact through distinct routing channels. The guide paths maintain wiring arrangement simplicity while ensuring insulation durability by eliminating intersection points.
Solution Approach 2:
The guide paths utilize the surface dimension of the projection to create separate routing planes for different transition wirings. By distributing wirings across different paths on the projection surface, the solution consolidates wirings in one location (on the projection) while preventing contact through dimensional separation of their routes, resolving the contradiction between compact arrangement and insulation durability.
3Ease of operation
If transition wirings are passed around the periphery of the stator outer circumference, then coils can be wired to each other, but the wirings are exposed to contact with housing or rotor
Solution Approach 1:
The projection with guide paths acts as an intermediary structure that elevates and secures the transition wirings away from the stator outer circumference periphery. The guide paths provide a protected routing channel that prevents direct exposure of wirings to the housing or rotor, while maintaining the connectivity function. This intermediary structure enables coil connectivity while eliminating mechanical contact risk.
Solution Approach 2:
The guide paths are pre-formed on the projection structure to predetermined locations that safely route transition wirings away from hazardous areas. By establishing the routing paths in advance during manufacturing, the wirings are guided along safe trajectories that prevent contact with housing or rotor, resolving the contradiction between connectivity and mechanical contact risk.
Data Source
AI summary
Plate-shaped projections are provided on a front insulator in such a manner as to project towards a front housing. In addition, projecting pieces are provided on a surface of each projection which confronts an inner circumferential surface of a stator housing. The projecting pieces are provided on each projection in such a manner as to form three rows which are parallel to an inner circumferential direction of the stator housing. Spaces between the respective rows constitute guide paths by which the transition wirings which connect between the coils are disposed on the projection in such a manner as to be spaced apart from each other.