Stator Tab Terminal Tangential Insertion for Simplified Assembly
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Solution Overview
Problem
The existing configuration of connection terminals in stators requires a dedicated automatic insertion machine with multiple-axis control, increasing running costs due to the need for complex mechanisms to handle different orientations.
Innovation Solution
The stator design features connection terminal insertion holes formed on a circle centered on the shaft center, allowing tab terminals with plate-shaped tabs to be inserted tangentially, simplifying the automatic insertion process and reducing equipment costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If connection terminals are placed in different orientations (parallel and perpendicular to windings), then the electrical connection function is achieved, but the automatic insertion machine requires multiple-axis control increasing running costs
Solution Approach 1:
The patent applies homogeneity by making all connection terminal insertion holes face the same radial direction (tangentially to a circle centered on the shaft center). This uniform orientation allows the automatic insertion machine to use a simple single-axis control system instead of complex multiple-axis control, thereby reducing running costs while maintaining the electrical connection function.
Solution Approach 2:
The patent uses asymmetry by positioning the insertion holes tangentially to a circle rather than radially outward from the center. This asymmetric arrangement allows all terminals to face the same direction, enabling simplified insertion machinery while achieving the required electrical connections between different phase windings.
2Adaptability or versatility
If dedicated automatic insertion machines with multiple-axis control are used, then connection terminals can be inserted in different orientations, but the device complexity and running costs increase
Solution Approach 1:
By standardizing all insertion holes to face the same radial direction, the patent enables a simple single-axis insertion machine to handle all terminals uniformly, eliminating the need for complex multiple-axis control mechanisms while maintaining full insertion capability.
Solution Approach 2:
The uniform tangential orientation of all insertion holes allows a single simplified insertion mechanism to serve all connection terminals across different phases, making the insertion machine more universal and reducing its overall complexity.
Data Source
AI summary
Provided is a stator of a rotating electric machine including: a stator core; windings of multiple phases wound around the stator core via insulators attached to the stator core; and tab terminals that each have at least one slit and a plate-shaped tab and that electrically connect an end portion of a winding, of one of the multiple phases, of the windings to an end portion of an other of the windings of a different one of the multiple phases, wherein a portion of each of the insulators or a resin component different from the insulators has a connection terminal insertion hole into which the tab terminal is inserted, and the connection terminal insertion hole is formed on a circle centered on a shaft center of the stator, and a plate surface of the tab of the tab terminal to be inserted into the connection terminal insertion hole is placed to be tangential to the circle.