Axially Movable Stator Terminal Pins for Automated Wire Twining
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Solution Overview
Problem
The miniaturization of electronic devices has made it challenging to automate the wire-twining process in small electric motors due to limited space between the stator core, coil, and circuit board, leading to difficulties in mechanizing the process and a risk of wire cutting during connection.
Innovation Solution
The stator unit design features axially spaced terminal pins that allow easy placement of a wire-winding machine needle, with terminal pins moved along a guide portion to connect wires to the coils without applying unnecessary tension, facilitating automated manufacturing and preventing wire cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the motor is miniaturized to reduce dimensions, then the size of the motor is reduced, but the space for wire-winding machine needle placement becomes insufficient
Solution Approach 1:
The terminal pin is made movable rather than fixed, allowing it to move in the axial direction to accommodate the wire-winding machine needle during the wire-twining process. This dynamic positioning enables automated manufacturing in miniaturized motors by providing temporary access space for the needle, then returning to its original position for compact assembly.
Solution Approach 2:
The terminal pin is given freedom to move in the axial dimension, which is perpendicular to the plane of the stator core and circuit board. This adds a degree of freedom in the axial direction, allowing the wire-winding machine needle to access the terminal pin from the axial direction without increasing the radial or lateral dimensions of the motor.
2Device complexity
If the terminal pin is fixed close to the stator core, then the motor structure is compact, but the wire may be cut during the pin insertion process
Solution Approach 1:
The terminal pin moves away from the stator core during the wire-twining process and returns to its original position afterward. This dynamic movement prevents the pin from interfering with the wire during insertion while maintaining compact structure during operation, thereby preserving both compactness and wire connection reliability.
Solution Approach 2:
The terminal pin moves to a predetermined position away from the stator core before the wire is inserted and twisted. This preliminary action creates sufficient space for the wire to be safely twisted around the pin without risk of being cut by the pin or surrounding structures, ensuring wire connection integrity before the pin returns to its compact position.
3Ease of manufacture
If the terminal pin is moved away from the stator core during wire connection, then the wire can be twisted without obstruction, but the motor structure becomes less compact
Solution Approach 1:
The terminal pin dynamically changes its position during manufacturing and returns to its original compact position after wire connection. This dynamic behavior allows easy wire connection during the process while maintaining compact motor structure in the final product, resolving the contradiction between manufacturing ease and structural compactness.
Data Source
AI summary
In manufacturing of the stator unit 2 according to one preferred embodiment of the present invention, a plurality of terminal pins are arranged in an axially spaced manner from a plurality of the coils during a twining process of the wires from the coils 232 to the terminal pins 241. Then, after the wire is twined to the terminal pins, the terminal pins connected to the coils are moved along the outer side face of the sleeve housing, functioning to as a guide portion 2201 for the terminal pins. By virtue of the configuration, the terminal pins 241 may be approximated to the coils without applying the tension on wire, and the stator unit may be made thin with preventing the open circuit of the wires.