Stator Wiring Frame for Brushless Motor Connections
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Solution Overview
Problem
Existing stators for brushless motors face challenges in providing a simple, economic, and reliable connection between coil terminals and a multiphase power supply.
Innovation Solution
A stator design featuring a wiring frame with conducting elements electrically insulated from each other, directly coupled to coil terminals to form multiphase windings, which are then easily connected to a multiphase power supply, utilizing an insulating holder to secure the phase terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional connection methods are used between coil terminals and power supply, then connection reliability may be maintained, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the connection function into the stator core structure itself by creating through-holes that directly receive coil terminals and power supply connections. This integration eliminates separate connection components and reduces overall device complexity while maintaining reliable electrical connections through the structured through-hole design.
Solution Approach 2:
The stator core is designed with multi-functionality by incorporating through-holes that simultaneously serve as structural elements and electrical connection pathways. These through-holes accommodate both coil terminals and power supply connections, allowing a single component to fulfill multiple functions and reduce the number of separate parts needed.
2Reliability
If complex connection structures are used, then connection reliability may be improved, but manufacturing cost and economic efficiency worsen
Solution Approach 1:
By combining the connection function into the stator core through integrated through-holes, the patent reduces the number of separate components that need to be manufactured and assembled. This merging approach simplifies the manufacturing process and reduces overall production costs while maintaining reliable connections.
Solution Approach 2:
The through-holes in the stator core are segmented into specific positions and configurations that accommodate different coil terminals and power supply connections. This segmentation allows for standardized manufacturing of the stator core with pre-defined connection points, reducing manufacturing complexity and cost.
3Device complexity
If simplified connection methods are used, then device complexity is reduced, but connection reliability may worsen
Solution Approach 1:
The stator core is pre-configured with through-holes during manufacturing that are specifically designed to accommodate coil terminals and power supply connections. This preliminary action ensures that the connection pathways are established before final assembly, improving reliability while maintaining simplicity in the final device structure.
Solution Approach 2:
The through-holes in the stator core act as intermediaries that facilitate reliable electrical connections between coil terminals and the power supply. These structured pathways provide a controlled and reliable connection medium that maintains electrical integrity while keeping the overall device structure simple.
Data Source
AI summary
A stator and a multiphase brushless electric motor utilizing the stator are provided. The stator which includes a stator core having a ring portion and a plurality of stator poles; a plurality of stator coils wound on the stator poles and having coil terminals; and a wiring frame fixed to the stator core, and comprising a plurality of conducting electrically insulated from each other. The conductor elements are electrically coupled to corresponding coils terminals to form multiphase windings. At least three coil terminals of the stator coils electrically coupled to respective conducting members are directly electrically coupled to a multi-phase power supply. The above stator can provide a simple, economic and reliable connection between the coil terminals and the multiphase power supply.