Stator Support Segmentation for Motor Wiring Assembly
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Solution Overview
Problem
The manufacturing process of bus bar units embedded in resin molded bodies for motors is complex due to the need for numerous processes and the complication of welding many coil wires and bus bars, which increases the complexity of motor wiring.
Innovation Solution
A stator design featuring a stator core with coil wires wound in a circular ring shape, supported by a first and second support member, where the first support member has receiving grooves guiding the coil wires and the second support member has through-holes to axially support the coil wires, allowing for improved assembly workability and reduced complexity by partially overlapping the first support member's grooves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bus bar units with multiple bus bars are embedded in a resin molded body, then electrical connection is achieved, but the manufacturing process becomes complex and requires numerous steps
Solution Approach 1:
The invention divides the support structure into two separate members: a first support member that supports the coil wires, and a second support member that supports the bus bars. This segmentation allows each member to be manufactured and assembled independently, reducing the complexity of embedding multiple bus bars in a single resin molded body while maintaining reliable electrical connections.
Solution Approach 2:
The invention extracts the bus bars from the resin molded body structure and places them on a separate second support member. This extraction simplifies the manufacturing process by eliminating the need to embed multiple bus bars within the resin, reducing the number of manufacturing steps while preserving the electrical connection function.
2Reliability
If many coil wires and bus bars are welded together, then electrical connectivity is established, but the welding process becomes complicated
Solution Approach 1:
The invention segments the electrical connection structure by separating coil wire support and bus bar support into different members. This reduces the number of welding points needed between coil wires and bus bars, as the separate support members provide structured alignment and reduce connection complexity.
Solution Approach 2:
The first and second support members act as intermediaries between the coil wires and bus bars. These support members provide a structured platform that facilitates easier connection, reducing the direct welding complexity between numerous coil wires and bus bars by introducing organized support structures.
3Reliability
If a complex bus bar unit structure is used, then electrical connection is achieved, but assembly workability decreases
Solution Approach 1:
The invention divides the support system into two manageable members with distinct functions. The first support member handles coil wire support with receiving grooves, while the second support member handles bus bar support with through-holes. This segmentation improves assembly workability by making each component simpler and more manageable, while maintaining reliable electrical connections.
Solution Approach 2:
The first support member is designed with receiving grooves that pre-position the coil wires, and the second support member has through-holes that pre-align the bus bars. These preliminary structural features guide the assembly process, making it easier to assemble the electrical connection components correctly without requiring complex alignment procedures.
Data Source
AI summary
A stator comprises: a stator core placed in a circular ring shape around a central axis that extends vertically, onto which coil wires are wound; a first support member placed over the stator core; and a second support member placed over the first support member, the first support member having receiving grooves for guiding the coil wires coming out of the stator core, wherein the receiving grooves are grooves that open to the top and extend in a direction along the top surface of the first support member, the second support member having through-holes that axially support the coil wires, wherein the second support member at least partially overlaps the receiving grooves of the first support member in an axial view.