Asymmetric Two-Piece Phase Separator for Electric Machine Windings
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Solution Overview
Problem
Conventional electric machines lack effective electrical insulation between windings, which can lead to electrical stresses, voltage spikes, and reduced reliability, especially during assembly and operation.
Innovation Solution
A two-piece phase separator with asymmetric endturn portions and positioning tabs, made from electrically insulating materials like paper or polymeric film, is used to provide robust electrical insulation between adjacent phase windings by overlapping and slidingly accommodating movement of winding endturn portions, ensuring effective separation and assembly stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional insulation methods are used between windings, then the structure is simple, but electrical insulation effectiveness is insufficient leading to electrical stresses and voltage spikes
Solution Approach 1:
The insulator is divided into multiple discrete components including a first insulator and a second insulator, each with specific leg portions and endturn portions. This segmentation allows each component to perform a specialized insulation function, improving overall electrical insulation effectiveness while maintaining manageable structural complexity through modular design.
Solution Approach 2:
The insulator incorporates an asymmetric endturn portion that is specifically configured to accommodate the asymmetric geometry of winding endturns. This asymmetric design provides optimized electrical insulation in critical areas where voltage stresses are highest, rather than using a symmetric design that would be less effective for the actual electrical stress distribution.
2Adaptability or versatility
If rigid insulation structures are used, then electrical insulation is provided, but the structure cannot accommodate movement of winding endturn portions during assembly and operation
Solution Approach 1:
The insulator design incorporates flexible or movable elements that allow the insulation structure to dynamically adapt to the movement of winding endturn portions during assembly and operation. This dynamic capability ensures continuous electrical insulation is maintained even when windings shift position, preventing electrical breakdown while accommodating necessary mechanical movement.
Solution Approach 2:
The insulator utilizes thin film or flexible insulating material that can conform to and accommodate the movement of winding endturn portions. This flexible insulation approach maintains electrical isolation between adjacent windings while allowing the necessary mechanical flexibility to handle assembly variations and operational movements without compromising insulation integrity.
3Adaptability or versatility
If overlapping insulator portions are used to accommodate winding movement, then adaptability is improved, but the device complexity increases
Solution Approach 1:
The overlapping insulation structure is achieved through segmentation into multiple insulator components rather than a single complex piece. This allows the overlapping configuration to be built from simpler, standardized components, reducing manufacturing complexity while maintaining the adaptability to accommodate various winding endturn positions through the overlapping arrangement.
Data Source
AI summary
A phase separator for an electric machine includes a first insulator and a second insulator. The first and second insulators each include a leg portion and an endturn portion connected to the leg portion. The endturn portion is asymmetric with respect to an axis defined by the leg portion such that the second insulator can be inverted and disposed in an overlapping arrangement for electrically insulating endturn portions of adjacent phase windings.