Stator Coil Winding Structure to Prevent Terminal Deformation
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Solution Overview
Problem
Existing electric rotary actuators, such as electric motors, face issues with increased outer shape and potential deformation of terminals due to excessive tensile force applied during winding, particularly in inner rotor-type configurations.
Innovation Solution
A coil winding portion structure for a stator that includes a tubular portion with load-receiving base and guide portions to support and guide the windings, reducing the load on connection terminals and allowing for compact sizing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the terminal is disposed to project to the outside of the stator to connect the winding end, then the winding can be connected to the terminal, but the outer shape of the entire motor increases
Solution Approach 1:
The terminal is nested within the stator bore, specifically positioned in the radial space between the coil wound portion and the outer peripheral portion of the stator. This allows the terminal to be accommodated inside the existing motor structure without increasing the outer shape, while still providing a connection point for the winding end.
Solution Approach 2:
Instead of extending the terminal radially outward from the stator, the terminal is positioned in the axial direction within the stator bore. This dimensional repositioning allows the terminal to connect the winding end without increasing the motor's radial outer shape.
2Productivity
If tensile force is applied to the winding by a winding machine during coil creation, then the winding can be wound in the coil, but the tensile force may be applied to the terminal causing deformation
Solution Approach 1:
A load receiving portion is introduced as an intermediary element between the winding and the terminal. This load receiving portion absorbs and bears the tensile force applied during the winding process, preventing the force from being transmitted to the terminal and causing deformation.
Solution Approach 2:
The load receiving portion is designed beforehand to cushion and absorb the tensile force that will be applied during the winding process. By preparing this protective structure in advance, the terminal is protected from deformation before the winding process begins.
Data Source
AI summary
In a motor unit that includes a stator including coils, a rotor, and an insulator attached to the stator, the insulator includes a bobbin portion around which a first coil wire or a second coil wire is wound, and a tubular portion provided outside the bobbin portion in a radial direction, terminals to which the first coil wire and the second coil wire are connected being mounted on the tubular portion, the tubular portion includes, at an upper end thereof between the coils and the terminals, base portions and guide portions receiving a load of the first coil wire or the second coil wire when the first coil wire or the second coil wire is wound in the coils such that the base portions and the guide portions are aligned in a circumferential direction.