Brushless Motor Stator Radial Outside Winding
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Solution Overview
Problem
Existing stators for inner rotor type brushless motors face challenges in manufacturing due to difficulties in winding coils efficiently, leading to low space factor, increased size, and higher costs, particularly when using nozzle winding machines, which slow down the winding process and require more machines.
Innovation Solution
A stator design with a ring-shaped yoke divided along the circumferential direction, allowing for easier coil winding from the radial outside using a flyer winding machine, increasing the space factor, reducing size, and lowering production costs by utilizing a faster winding process and minimizing the number of machines needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a nozzle winding machine is used to wind coils on tooth portions from radial inside, then coils can be wound on inner rotor type motor stator, but winding speed decreases and more machines are required
Solution Approach 1:
The patent inverts the conventional winding approach by winding coils from the radial outside instead of radial inside. This is achieved by configuring the stator with tooth portions protruding toward radial inside and using a flyer winding machine that feeds coils from the outside, thereby enabling high-speed winding while maintaining compatibility with inner rotor type motors
Solution Approach 2:
The patent replaces the nozzle winding machine mechanism with a flyer winding machine mechanism. The flyer winding machine uses a rotating flyer to guide the coil wire around the tooth portions, enabling continuous high-speed winding without the need for axial sliding motions required by nozzle machines
2Ease of manufacture
If nozzle winding machine is used, then coils can be wound on tooth portions, but space factor decreases due to required movement space
Solution Approach 1:
The patent inverts the winding direction from radial inside to radial outside, which eliminates the need for axial movement space. The flyer winding machine winds coils by rotating around the tooth portions from the outside, allowing tooth portions to be closely arranged and maximizing the space factor
3Adaptability or versatility
If yoke is modified for inner rotor type motor with tooth portions protruding toward radial inside, then it fits inner rotor configuration, but coil winding becomes difficult from radial outside
Solution Approach 1:
The patent inverts the conventional winding approach by winding from radial outside instead of radial inside. The stator is designed with tooth portions protruding toward radial inside, and the flyer winding machine is configured to feed and wind coils from the radial outside, making coil winding easy while maintaining inner rotor type compatibility
Data Source
AI summary
An inner rotor type brushless motor includes a stator. The stator is made of a plurality of stator sections. Each one of the stator sections has a plurality of core members, an insulator, and a winding wound on the core members via the insulator. The core member includes a yoke portion and a tooth portion. The insulator includes a ring portion to connect the core members. Since each stator section can provide sufficient distance and space between two core members on the same stator section, it is easy to wind the winding on the tooth portions. The stator sections can be assembled along an axial direction to form the stator. The yoke portions are circumferentially arranged to connect each other to form a magnetic path.