Stepping Motor Terminal Structure Linear Arrangement
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Solution Overview
Problem
The existing PM stepping motor designs face challenges in increasing the number of motor steps for enhanced torque and resolution, as increasing the number of magnetic poles and pole teeth reduces the width of each pole tooth, making it difficult to arrange terminals in two arrays without increasing the motor's axial dimension.
Innovation Solution
A biforked terminal structure is implemented, allowing magnet wire connection without solder, with terminals arranged in a line orthogonal to the axial direction, enabling reduced axial length and increased distance between terminals, facilitating easier winding and downsizing of the motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the number of magnetic poles and pole teeth is increased to enhance torque and resolution, then the motor steps are increased, but the width of each pole tooth is reduced making it difficult to arrange terminals
Solution Approach 1:
The patent transitions from a conventional two-array terminal arrangement (requiring space in multiple directions) to a linear terminal arrangement where all terminals are disposed in a single line along the axial direction. This dimensional reorganization allows terminals to be arranged compactly without requiring lateral space, thus accommodating high-resolution designs with many pole teeth while maintaining ease of terminal access and connection.
2Ease of operation
If terminals are arranged in two arrays to facilitate connection, then ease of operation is improved, but the axial dimension of the motor increases
Solution Approach 1:
The patent merges the terminal arrangement from two separate arrays into a single linear array along the axial direction. By combining what were previously distributed terminal groups into one compact linear configuration, the design achieves both compact axial dimension and maintained ease of operation, as all terminals remain accessible in a single organized line without requiring lateral separation.
3Productivity
If the width of pole teeth is reduced to increase their number, then motor steps are increased, but the axial space for terminal arrangement becomes insufficient
Solution Approach 1:
The patent reorganizes terminal arrangement from a lateral two-array configuration to an axial linear configuration. This allows terminals to be arranged along the axial direction where space is available, rather than requiring lateral space that would be consumed by increased pole tooth count. The linear axial arrangement efficiently utilizes the available axial dimension without interfering with the compact pole tooth design needed for high motor steps.
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 configuration allows for a more compact stepping motor design with improved workability during winding, enabling increased torque and resolution without hindering the winding process, while maintaining environmental sustainability by eliminating solder use.
Implementation Method 1
The ends of the coil winding may be reliably connected electrically to the terminals by, for example, plasma welding (fusion processing) rather than by using a soldering method.
Data Source
AI summary
A stepping motor includes: a cylindrical rotor assembly disposed around the rotation axis; a stator assembly including two stator units disposed around the rotor assembly and axially coupled to each other; and a terminal structure disposed at the axial center of the outer circumference of the stator assembly. The terminal structure includes: a terminal block cluster composed of four terminal blocks; and four terminals fixed respectively to the four terminal blocks. The four terminals each include: an internal connection portion to which one of two wire ends of the winding is connected; and an external connection portion which is disposed substantially parallel to the internal connection portion and which is connected to a driving circuit disposed externally. The four terminals are arranged in a line along a direction substantially orthogonal to the rotation axis, and the internal connection portion and the external connection portion are aligned along the rotation axis.