Annular Stopper Radial Gap Design for Stator Resin Integrity
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Solution Overview
Problem
In electric machines, the resin used to fill gaps in stator windings often breaks and forms crumbs due to uneven gap sizes between the stopper and stator end disc, leading to uncontrolled distribution and potential malfunction.
Innovation Solution
An annular stopper design with a radial gap of constant thickness between the stopper and stator end disc, filled with the same resin as the stator windings, ensures complete resin curing without breaking, preventing resin crumbs from entering the machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gap between stopper and stator end disc is large, then complete resin draining is achieved, but the cured resin breaks and forms crumbs
Solution Approach 1:
The patent changes the geometric parameters of the stopper by providing annular grooves at different radial positions, creating multiple smaller gaps instead of one large gap. This parameter modification allows the resin to be retained in controlled small volumes that cure without breaking, while still achieving sufficient draining to prevent harmful resin accumulation.
Solution Approach 2:
The stopper is segmented into multiple annular regions with grooves at different radial positions, dividing the single large gap into multiple smaller gaps. This segmentation prevents the formation of large resin clusters that would break during curing, while the combined effect of multiple gaps still achieves adequate resin drainage.
2Ease of manufacture
If the stopper is non-annular with local stoppers, then manufacturing is simpler, but the gap thickness is uneven causing resin breaking
Solution Approach 1:
The stopper incorporates annular grooves at specific radial positions to create localized gaps of controlled thickness. This local quality modification allows the stopper to maintain a simple annular overall shape for easy manufacturing, while introducing localized features that ensure uniform gap thickness in critical areas to prevent resin breaking.
Solution Approach 2:
The invention transitions from a simple planar stopper design to a three-dimensional annular structure with grooves at varying radial positions. This dimensional enhancement allows precise control of gap thickness through radial positioning of grooves, achieving manufacturing precision without complicating the basic annular form that remains easy to manufacture.
3Strength
If resin is completely drained, then mechanical stability is improved, but resin crumbs are formed and distributed uncontrolled
Solution Approach 1:
The annular grooves in the stopper beforehand cushion the resin by providing controlled retention zones. These grooves ensure that small amounts of resin are held in controlled environments where they can cure without breaking, preventing the formation of harmful crumbs while still achieving sufficient drainage for mechanical stability.
Solution Approach 2:
The annular grooves act as intermediary structures between the large gap (which needs draining) and the stator windings (which need protection). These grooves mediate the resin drainage process by providing intermediate retention zones that control the curing process and prevent harmful crumb formation while maintaining mechanical stability.
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 solution prevents resin crumbs from entering the electric machine, ensuring proper function by maintaining a consistent gap size and ensuring complete resin curing, thus avoiding mechanical instability and malfunction.
Implementation Method 1
flooding the interior of the arrangement with a resin, draining the resin, wherein a radial gap between the stopper, which has an annular shape, and the stator end disc remains filled with the resin and curing the resin
Data Source
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AI summary
An arrangement for an electric machine (1) is disclosed, which comprises a housing (12) with a stopper (13) and a stator (4) arranged in the housing (12). The stator (4) comprises a stator lamination stack (6), stator windings (7) and a stator end disc (8a, 8b) arranged on the axial end of the stator lamination stack (6). In the mounted position, the stator lamination stack (6) on the axial end, on which the stator end disc (8a, 8b) is arranged, is in body contact with the stopper (13) of the housing (12). In detail, the stopper (13) has an annular shape thereby providing a radial gap (b) between the stopper (13) and the stator end disc (8a, 8b). Moreover, the invention relates to a method for manufacturing such an arrangement, an electric machine (1) having such an arrangement and a vehicle (16) having such an electric machine (1).