Conductive Wire Routing Structure With Insulated Guide Locking
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Solution Overview
Problem
Conventional stator designs with conductive wire locking portions integrated into resin molded insulators complicate manufacturing and increase the risk of short circuits due to complex structures.
Innovation Solution
A routing structure for conductive wires featuring a body portion, a guide portion with a protruding portion, and insulating portions to isolate the guide and body portions, allowing the conductive wire to be hooked onto the guide portion, which is then press-fitted and fixed, simplifying the structure and reducing the risk of short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conductive wire locking portion is integrally formed with the insulator as a resin molded body, then the conductive wire can be securely locked, but the structure becomes complicated and manufacturing becomes difficult
Solution Approach 1:
The conductive wire locking portion is separated from the insulator body and implemented as a独立 guide portion that can be attached to the insulator. This segmentation simplifies the insulator structure while maintaining the locking function through the guide portion's protruding portion that hooks onto the conductive wire.
Solution Approach 2:
The conductive wire locking function is extracted from the insulator and implemented as a separate guide portion. This allows the insulator to have a simple resin molded body without complex integral structures, while the guide portion provides the necessary locking capability through its protruding portion.
2Reliability
If the conductive wire locking portion is integrally formed with the insulator, then the conductive wire can be locked, but the manufacturing process becomes complicated
Solution Approach 1:
By separating the guide portion from the insulator body, the insulator can be manufactured as a simple resin molded body using conventional processes, while the guide portion can be manufactured separately and attached. This segmentation significantly simplifies the manufacturing process compared to forming complex integral structures.
Solution Approach 2:
The guide portion is attached to the insulator to combine the simple resin molded insulator with the conductive wire locking function. This merging achieves the desired reliability while maintaining manufacturing simplicity, as each component can be optimized and manufactured independently before assembly.
3Reliability
If the guide portion is pressed and fixed from the body portion, then the conductive wire can be securely attached, but the guide portion must protrude by a length longer than the conductive wire radius
Solution Approach 1:
The guide portion is designed with a protruding portion that extends beyond the body portion by a specific length (longer than the conductive wire radius) only where needed for conductive wire attachment. This localized protrusion provides secure attachment while minimizing the overall protrusion length, and the protruding portion can be locally reinforced if needed.
Data Source
AI summary
A routing structure of a conductive wire includes: a body portion; a guide portion fixed to the body portion and including a protruding portion protruding to an outside of the body portion; a conductive wire hooked on the protruding portion of the guide portion; and a first insulating portion disposed between the body portion and the guide portion and insulating the body portion and the guide portion.