Stator Lead-Out Terminal Assembly for Stable Wire Welding
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Solution Overview
Problem
Existing stator designs face challenges in achieving stable connections between lead-out wires and terminals due to press-fitting methods, leading to potential loosening and unsatisfactory contact.
Innovation Solution
A stator assembly design featuring an insulating frame, wire outlet base, cover plate, and terminals with bent portions and holder seats to secure lead-out wires, allowing for stable welding and reduced misalignment, along with a cover plate to protect and facilitate automated production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If press-fitting method is used to fix lead-out wire in wiring slot, then installation is facilitated, but connection stability deteriorates and loosening occurs
Solution Approach 1:
The patent introduces a terminal as an intermediary component between the lead-out wire and the wiring slot. The terminal includes a pressing piece that press-fits the lead-out wire, a welding piece for stable electrical connection, and a wire guiding piece that guides the wire into position. This intermediary structure separates the mechanical fixation function from the electrical connection function, allowing press-fitting to be used for installation ease while maintaining connection stability through additional welding and guiding mechanisms.
2Volume of moving object
If high miniaturization requirements are imposed on stator, then slot fill rate is improved, but lead-out wire leading becomes more difficult
Solution Approach 1:
The patent extends the wire outlet base outward from the stator core in a direction away from the stator, creating additional spatial dimension for wire leading. This external wire outlet base provides a dedicated area for terminal installation and wire routing that does not consume space within the stator's miniaturized structure, thereby resolving the conflict between compact stator design and wire leading requirements.
3Reliability
If welding connection is used for lead-out wire and terminal, then connection stability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple functions into the terminal component: the pressing piece for mechanical fixation, the welding piece for electrical connection, and the wire guiding piece for wire positioning. By merging these functions into a single integrated terminal, the design achieves stable welding connections without proportionally increasing overall manufacturing complexity, as the terminal is installed as one component rather than multiple separate parts.
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
Improves the stability and efficiency of lead-out wire connections, reducing the likelihood of loosening and enhancing production efficiency through automated processes.
Implementation Method 1
each of the first terminals is located between one of the first holder seats and one of the second holder seats, and each of the first lead-out wires is clamped in and held by one of the first holder seats and one of the second holder seats
Implementation Method 2
each of the first welding portions is used for welding a corresponding first lead-out wire
Data Source
AI summary
A stator assembly and a motor are provided. The stator assembly incudes an insulating frame, a winding, a wire leading-out base, a cover plate, and a plurality of first terminals. The winding is wound around the insulating frame and includes a plurality of first lead-out wires; the wire leading-out base is provided with a plurality of first mounting positions; the cover plate is connected to the wire leading-out base and covers the plurality of first mounting positions; the plurality of first terminals are arranged in one-to-one correspondence with the plurality of first mounting positions; each of the first terminals includes a first welding portion and a wire leading-out portion; each of the first welding portions is used for welding a corresponding first lead-out wire; and the plurality of wire leading-out portions penetrate through the cover plate.