Arc-Shaped Stator Terminal Block for Compact Motor Assembly
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Solution Overview
Problem
Current stator designs with terminal blocks superimposed on the stator core face challenges in reducing manufacturing costs and size due to their structural configuration.
Innovation Solution
A stator design featuring a terminal block with an arc-shaped base, engaging portions, and an arm that connects these elements, allowing for reduced dimensions and material usage, thereby minimizing the stator's size and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the terminal block is formed to be superimposed with the stator core as a whole, then the structural integrity is maintained, but the manufacturing cost and size cannot be reduced
Solution Approach 1:
The terminal block is segmented into a base and an arm that are formed separately and then assembled together. The base is formed in an arc shape and the arm is formed separately to connect the base to the engaging portion, allowing for reduced material usage and manufacturing cost while maintaining structural integrity through the connection between base and arm
Solution Approach 2:
The base is formed in an arc shape rather than a straight line, utilizing the circumferential dimension to follow the curvature of the stator core. This dimensional adaptation allows the terminal block to integrate with the stator core's geometry while reducing the radial dimension and material requirements
2Stability of the object's composition
If the terminal block is formed to be superimposed with the stator core as a whole, then the structural completeness is ensured, but the size reduction is limited
Solution Approach 1:
The terminal block is divided into a base and an arm component. The base extends in an arc shape to provide structural completeness for electrical connection, while the arm provides the necessary engagement function. This segmentation allows each component to be optimized for its specific function, reducing overall volume while maintaining structural completeness
Solution Approach 2:
The arm is extracted as a separate functional element from the base, connected via a connection portion. This extraction allows the base to be minimized to only the essential arc-shaped structure needed for electrical connection, while the arm provides the engagement function with minimal material usage
3Device complexity
If the base and engaging portion are directly connected, then the structural simplicity is achieved, but the radial dimension increases
Solution Approach 1:
Instead of directly connecting the base and engaging portion in the radial direction, an arm is introduced that extends in the circumferential direction. This dimensional change allows the base to be positioned closer to the stator core while the arm reaches to provide engagement, thereby reducing the radial dimension of the terminal block
Data Source
AI summary
A stator includes a terminal unit disposed on a first side in an axial direction with respect to a stator main body, and the terminal unit includes a base extending in an arc shape in a circumferential direction following the stator main body, a first inner side engaging portion provided on an inner circumferential edge of the base, an outer side engaging portion provided on an outer circumferential edge of the base, and an arm extending from the outer circumferential edge of the base in the radial direction and continuous with the outer side engaging portion.