Stator Assembly Terminal Nesting for Motor Reliability
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Solution Overview
Problem
Conventional motor stator assemblies face issues with terminal breakage due to external impacts and require additional space for terminal seating, leading to increased axial length and exposure to damage.
Innovation Solution
A stator assembly design featuring a three-phase terminal inserted between insulators, with a ring-shaped structure divided into parts, including streamlined terminal bodies, inverter connecting portions, and coil engaging portions, which are partially exposed and protected by insulators, reducing external exposure and enhancing insulation and assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal is coupled onto the insulator arranged on the top of the stator core, then the terminal can be electrically connected, but the terminal is often broken away from the stator core by external impact and the axial length of the motor increases
Solution Approach 1:
The terminal is inserted into a cavity formed within the insulator, creating a nested structure where the terminal resides inside the insulator volume rather than being mounted on its outer surface. This eliminates the need for additional axial space while providing mechanical protection against external impacts, thereby maintaining reliable electrical connection without increasing the motor's axial length
2Reliability
If the terminal is coupled to the outside of the insulator, then electrical connection is achieved, but a separate space for seating the terminal is required and many parts of the terminal are exposed to the outside making it vulnerable to damage
Solution Approach 1:
The terminal cavity is integrated directly into the insulator structure, merging the functions of electrical insulation and terminal mounting into a single component. This eliminates the need for separate terminal seating structures while providing protection for the terminal, thereby reducing assembly complexity and improving terminal protection without requiring additional parts
Data Source
AI summary
Disclosed herein is a stator assembly for a motor. The stator assembly comprises a stator core having a plurality of teeth around each of which a stator coil is wound, a first insulator coupled to one side of the stator core to provide insulation between one tooth and an adjacent tooth, a second insulator coupled to the other side of the stator core to provide insulation between one tooth and an adjacent tooth, and a three-phase terminal inserted between the stator core and the second insulator and protruded partially to the outside of the second insulator to be electrically connected to an inverter. According to the present invention, there are advantageous effects that since the three-phase terminal is assembled between insulators, breakaway and breakage of the three-phase terminal can be prevented and that insulation effect and assembly capability thereof are enhanced.