Stator Tooth Wire Retention Wings for Electric Motors
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Solution Overview
Problem
In electric motor designs with reduced tooth head dimensions, securing wire coils on the stator teeth is challenging, especially when fly winding requires access between adjacent teeth, as existing retention structures fail to effectively balance wire retention and winding process compatibility.
Innovation Solution
An overmolded stator with wire retention wings extending circumferentially between the teeth, integrated into the stator core, provides secure wire retention while allowing access for winding processes, using a dual-out stator lamination design with arcuately spaced teeth and overmolding that defines wire routing and mounting structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If tooth head dimensions are reduced, then motor size and weight are reduced, but wire retention capability deteriorates
Solution Approach 1:
The tooth head is segmented into functional zones: a first portion for wire retention and a second portion for winding access. This segmentation allows each zone to be optimized independently - the first portion provides retention structure while the second portion maintains access for fly winding, resolving the contradiction between reduced dimensions and retained functionality.
Solution Approach 2:
The invention introduces a circumferential dimension to wire retention by creating retention portions that extend around the tooth head periphery. This circumferential retention structure provides enhanced wire holding capability in a compact radial space, allowing effective retention without increasing tooth head volume.
2Reliability
If retention structures are added to secure wires, then wire retention capability is improved, but access for fly winding process is blocked
Solution Approach 1:
The tooth head is divided into distinct functional portions: retention portions that secure wires and second portions that remain open for winding access. This segmentation ensures that retention structures are localized and do not obstruct the winding path, allowing both wire security and process accessibility.
Solution Approach 2:
Different regions of the tooth head are given different functional qualities - the first portions have retention characteristics with circumferential structures, while the second portions maintain open access characteristics. This local differentiation allows wire retention where needed without blocking winding operations elsewhere.
3Productivity
If tooth head dimensions are reduced, then motor productivity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The tooth head is segmented into standardized retention portions and access portions, allowing modular manufacturing. This segmentation enables the use of precision-forming techniques on discrete sections rather than requiring ultra-precise monolithic tooth geometry, maintaining manufacturing feasibility while achieving compact dimensions.
Solution Approach 2:
The invention optimizes geometric parameters of the retention portions (such as circumferential extension and depth) to achieve maximum retention effectiveness within reduced dimensions. By carefully selecting and optimizing these parameters, the design achieves high productivity without requiring extreme manufacturing precision.
Data Source
AI summary
An overmolded stator for use in an electric motor is disclosed. The stator core includes a yoke and a plurality of arcuately spaced apart teeth extending at least substantially radially from the yoke. Each of the teeth presents opposite axially spaced apart endmost surfaces, a leg extending generally radially from the yoke, and a head extending generally arcuately relative to the leg to present opposite head ends spaced from the leg. A pair of wire retention wings extend at least substantially circumferentially outwardly relative to each of the teeth.