Armature Winding Insulation Layout for High-Voltage Phase Separation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing rotating electric machines face challenges in ensuring adequate insulation between coils of differing phases when high voltage is applied, particularly in armature windings with overlapping former-wound coils.

Innovation Solution

The rotating electric machine incorporates a design with partial windings having intermediate conductor portions separated by insulation covering bodies, where sheet-shaped insulation is provided between conductor portions and supporting members, and insulation covers are used in crossover portions, enhancing inter-phase and ground insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If former-wound coils are used in overlapping arrangement, then the armature winding structure is simplified, but insulation between coils of differing phases deteriorates under high voltage

Engineering Contradiction:

Improvearmature winding structureVSAvoidinsulation performance

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent divides the armature winding into multiple partial windings, each consisting of discrete conductor portions (first, second, third conductor portions) that are separately insulated and assembled. This segmentation allows for targeted insulation treatment at critical interfaces while maintaining the overall simplified overlapping structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces insulation covering bodies as intermediary elements between conductor portions of different phases. These covering bodies are specifically placed at overlapping regions where insulation is most critical, acting as mediators that prevent electrical breakdown without complicating the overall winding structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If insulation covering bodies are added between conductor portions, then insulation performance is improved, but device complexity increases

Engineering Contradiction:

Improveinsulation performanceVSAvoidinsulation structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies insulation covering bodies only at specific critical locations where conductor portions of different phases overlap or come into close proximity, rather than providing uniform insulation throughout. This local quality approach ensures insulation performance is improved at critical interfaces without unnecessarily increasing overall device complexity.

Inventive Principle:

Principle #3Local quality

3Reliability

If intermediate conductor portions are separated by insulation covering bodies, then inter-phase insulation is enhanced, but manufacturing complexity increases

Engineering Contradiction:

Improveinter-phase insulationVSAvoidassembly process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent incorporates insulation covering bodies into the partial windings during the winding formation process itself, rather than adding them separately during final assembly. This preliminary action ensures insulation is already in place before the partial windings are assembled into the complete armature winding, simplifying the manufacturing process.

Inventive Principle:

Principle #10Preliminary action

4Reliability

If insulation covers are provided in crossover portions, then ground insulation is improved, but dead space increases

Engineering Contradiction:

Improveground insulationVSAvoiddead space

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent employs thin sheet-shaped insulation covering bodies in the crossover portions where conductors change direction. These thin film structures provide necessary ground insulation without occupying significant space, thereby minimizing dead space while maintaining reliability.

Inventive Principle:

Principle #30Flexible shells and thin films

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 maintains insulation performance even under high voltage, ensuring favorable insulation properties and reducing dead space, thereby improving the overall efficiency and reliability of the armature winding.

Implementation Method 1

A sheet-shaped insulation covering body is provided in the intermediate conductor portion in a portion that opposes the intermediate conductor portion of the partial winding of another phase

Methodology Applied

Scientific EffectElectrical insulation: Electrical Resistance

Data Source

PatentUS12519362B2Rotating electric machine

Publication Date: 2026.01.06 DENSO CORP

AI summary

An armature winding of multiple phases has a phase winding that is made of a plurality of partial windings for each phase. The partial winding includes a pair of intermediate conductor portions and crossover portions that connect the pair of intermediate conductor portions in an annular shape, and is configured by a conductor material being wound in multiple layers in the pair of intermediate conductor portions and the crossover portions. The intermediate conductor portions of the phases are arrayed in a predetermined order in the circumferential direction by one of the intermediate conductor portions of the pair of intermediate conductor portions of the partial winding of another phase being arranged between the pair of intermediate conductor portions of the partial winding. A sheet-shaped insulation covering body is provided in the intermediate conductor portion in a portion that opposes the intermediate conductor portion of the partial winding of another phase.