Stator Segment Wire Notches for Bus Bar Lead Alignment
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Solution Overview
Problem
Existing electric motor stator designs face challenges in efficiently connecting and securing stator windings to bus bar assemblies, leading to potential misalignment and reduced motor performance.
Innovation Solution
The design incorporates a standoff portion on the insulator yoke of stator segments with recessed wire notches that protrude axially and radially to securely receive and guide wire leads, ensuring proper electrical connection and alignment with the bus bar assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional stator designs without standoff portions and wire notches are used, then the structure is simpler, but the wire leads cannot be securely received and aligned, leading to potential misalignment and reduced motor performance
Solution Approach 1:
The wire notches are pre-formed in the standoff portions of the insulator yoke before assembly, allowing the wire leads to be securely received and aligned during assembly without requiring additional alignment steps or complex fastening mechanisms
Solution Approach 2:
The standoff portion with wire notches acts as an intermediary structure between the insulator yoke and the wire leads, providing a dedicated interface that secures the wire leads and ensures proper alignment with the bus bar assembly
2Manufacturing precision
If wire leads are not securely received, then the structure is simpler, but misalignment occurs leading to reduced motor performance
Solution Approach 1:
The wire notches are localized features formed in specific positions on the standoff portions, providing precise alignment points for the wire leads at critical locations without requiring the entire stator structure to be complex
Data Source
AI summary
An electric motor may include a rotor assembly including a rotor shaft. An electric motor may include a stator assembly including a plurality of stator segments arranged adjacent one another in a circumferential direction of the stator assembly, at least one stator segment including a core having a core yoke portion and a core tooth portion, an insulator at least partially covering the core and having an insulator yoke portion and an insulator tooth portion, a stator segment yoke portion formed by the core yoke portion and the insulator yoke portion, a stator segment tooth portion formed by the core tooth portion and the insulator tooth portion, and a stator winding extending about the stator segment tooth portion including a wire lead. The insulator yoke portion includes a standoff portion that defines a wire notch. The wire notch at least partially receives the wire lead.