Asymmetric Phase Separator for Stator Winding Insulation

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Solution Overview

Problem

Conventional stator winding insulation methods in electrical machines are not adequately addressing the need for improved manufacturability and ease of use, particularly in lap wound stators where phase-to-phase shorts can occur due to the close proximity of windings, necessitating effective electrical insulation between adjacent phase windings.

Innovation Solution

A phase separator with a midsection and asymmetric end portions is designed to physically and electrically isolate adjacent phase windings in electrical machines, featuring longitudinally extending slots and arcuate edges that securely fit between stator teeth, using insulation materials like dielectric paper or film to prevent shorts and facilitate lacing cord installation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional insulation methods are used between adjacent phase windings, then electrical insulation is provided, but manufacturability and ease of use are not improved

Engineering Contradiction:

Improvemanufacturability of stator windingsVSAvoidcomplexity of insulation structure

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The phase separator is divided into three functional segments: a midsection for fixing in stator gaps, and two end portions for separating end turns. This segmentation allows each part to perform its specific function optimally while simplifying the overall manufacturing process compared to conventional single-piece insulation methods.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The phase separator is pre-cut and pre-shaped with specific geometric features (slots, arcuate edges, asymmetric design) before installation. This preliminary preparation enables easier and faster installation during stator winding assembly, improving manufacturability without requiring complex on-site adjustments.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If phase windings are placed in close proximity for efficient space utilization, then productivity is improved, but phase-to-phase shorts become more likely

Engineering Contradiction:

Improvespace utilization efficiencyVSAvoidelectrical insulation reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The phase separator acts as an intermediary component placed between adjacent phase windings. It provides both physical separation and electrical insulation, enabling close proximity placement for space efficiency while simultaneously preventing phase-to-phase shorts through its insulating material construction.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The phase separator provides localized electrical insulation precisely where needed between adjacent phase windings. The insulating material is applied in the specific regions requiring protection, allowing efficient space utilization while maintaining reliability through targeted insulation rather than blanket coverage.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If a symmetric phase separator design is used, then manufacturing is simplified, but proper engagement with asymmetric stator teeth and windings is compromised

Engineering Contradiction:

Improvesimplicity of separator designVSAvoidengagement accuracy with stator features

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The phase separator employs asymmetric design in its end portions to match the asymmetric arrangement of stator teeth and phase windings. This asymmetry ensures proper engagement and alignment with the specific geometric features of the stator, improving manufacturing precision and installation accuracy while remaining manufacturable through standard cutting processes.

Inventive Principle:

Principle #4Asymmetry

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

The phase separator effectively insulates adjacent phase windings, enhancing the manufacturability and reliability of electrical machines by preventing phase-to-phase shorts and providing stable electrical insulation during operation, while simplifying the installation process through its pre-cut shape and design.

Implementation Method 1

using insulation materials like dielectric paper or film to prevent shorts

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS9369020B2Phase separators for electrical machines

Publication Date: 2016.06.14 HAMILTON SUNDSTRAND CORP

AI summary

A phase separator for an electrical machine includes a first end portion, a second end portion, and a midsection. The midsection connects the first end portion to the second end portion such that the first end portion opposes the second end portion. The midsection is configured for fixing the phase separator in the electrical machine for separating the adjacent phase windings from one another. The first and second end portions are for separating end turns of adjacent phase windings of an electrical machine.