Motor Stator Wire Connection Segmentation for Radial Size Reduction
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Solution Overview
Problem
Conventional motor stators with concentrated winding designs face challenges in downsizing due to radial protrusion of wire connection portions, leading to increased product dimensions.
Innovation Solution
The motor stator design features separate connections for terminal wires, with the first and second wires connected in one wire connection portion and the second and third wires connected in another, spaced portion, allowing for brazing and press fitting into the insulator's groove, reducing the number of wires connected at a single point and enabling a more compact configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If three terminal wires are bundled and connected together at one wire connection portion on the radially outer side, then the neutral point is formed, but the wire connection portion protrudes radially outward increasing the product dimension
Solution Approach 1:
The patent divides the single wire connection portion into multiple separate wire connection portions. Specifically, the three terminal wires are connected in pairs at different locations: first and second terminal wires are connected at a first wire connection portion, while the second and third terminal wires are connected at a second wire connection portion. This segmentation eliminates the need for a single large bundled connection, allowing each connection portion to be more compact and not protrude radially outward.
2Volume of moving object
If terminal wires are bent inward after connection at the neutral point, then the wires are positioned inside the core, but bending forming is required which complicates the manufacturing process
Solution Approach 1:
The patent performs the wire connection at multiple separate portions before the wires would need to be bent inward. By connecting terminal wires in pairs at different locations (first and second wires at one location, second and third wires at another), the connection is established in a more accessible position, eliminating or reducing the need for complex bending operations after connection.
3Reliability
If the insulator houses the wire connection portion, then insulation is provided, but the insulator must protrude radially outward to accommodate the wire connection portion
Solution Approach 1:
By segmenting the wire connection into multiple separate portions, each connection portion can be housed within the insulator without requiring the insulator to protrude radially outward. The distributed connection points allow the insulator to contain all connections within its normal radial boundary, eliminating the need for additional protrusion to accommodate a single large wire bundle.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach eliminates the need for bending and reduces the radial size of the motor stator by minimizing the number of terminal wires connected at a single point, resulting in a more compact product without protrusion and improved insulation and vibration resistance.
Implementation Method 1
the first and second terminal wires or the second and third terminal wires are connected together by brazing in the first or second wire connection
Data Source
AI summary
In a motor stator, terminal wires of a coil are led out respectively from a feed-side and a neutral-side coil end. With three circumferentially adjacent first-, second-, and third-phase coils as one set, the leading end portion and intermediate portion of one of three terminal wires led out from the neutral side are connected to each of the remaining terminal wires. A structure wherein the first- and second-phase terminal wires are connected together in one position, and the second- and third-phase terminal wires are connected together in a different position from the one position, is adopted, thus compacting the size of one wire connection portion.