Rotating Electrical Machine Coil Insulating Tape Winding
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Solution Overview
Problem
Existing methods for impregnating rotating electrical machine coils with insulating resin, such as those using jigs or heat shrinkable tapes, face challenges like increased man-hours, space requirements, and variability in insulation properties, particularly in suppressing bulges and preventing voids or peeling of the main insulating layer.
Innovation Solution
A method involving multiple windings of insulating tape around the coil conductors, with an adhesive member applied to adhere the tape layers, ensuring uniform coverage and adhesion to prevent bulges and voids, allowing for both automated and manual winding processes without significant changes to conventional steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a jig is used to press the coil during impregnation curing, then the main insulating layer is formed without voids or peeling, but the production process requires significantly increased man-hours and space for arranging and removing jigs
Solution Approach 1:
The insulating tape is wound around the coil conductor with adhesive applied in advance, creating a pre-formed insulating structure that maintains its shape during impregnation curing without requiring external pressing jigs. This preliminary preparation of the insulating layer eliminates the need for subsequent mechanical pressing operations.
Solution Approach 2:
The adhesive on the insulating tape enables the layer to adhere to itself and the coil conductor autonomously, forming a stable insulating structure without requiring external pressing devices. The material itself provides the necessary holding force during the impregnation curing process, eliminating dependency on additional equipment.
2Manufacturing precision
If a heat shrinkable slot corona protection layer is extended to the protruded part, then the main insulating layer is protected from voids and peeling, but the method cannot be applied to coils that do not require slot corona protection and increases variation in corona protection layer sizes
Solution Approach 1:
The insulating structure is divided into two independent components: the main insulating layer formed by insulating tape wound around the coil conductor, and the slot corona protection layer. This segmentation allows the main insulating layer to be universally applied to all coil types while the corona protection layer can be selectively added only when slot corona protection is required.
Solution Approach 2:
The insulating tape with adhesive is applied specifically to the protruded part of the coil conductor where it is most needed for preventing voids and peeling during impregnation curing. This localized application provides precise protection where required without unnecessarily modifying other parts of the coil or adding universal corona protection layers to all coils.
3Manufacturing precision
If multiple layers of insulating tape are wound around the coil conductor, then uniform coverage and adhesion are achieved to prevent bulges, but the winding process requires precise control to maintain consistency
Solution Approach 1:
The insulating tape is wound continuously around the coil conductor in multiple layers with adhesive applied throughout the winding process. This continuous winding action ensures uniform coverage and consistent adhesion across all layers, preventing bulges and maintaining homogeneity of the insulating layer without requiring intermittent stopping or complex adjustment mechanisms.
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 approach effectively suppresses ununiform bulges and prevents voids or peeling in the insulating layer, enhancing insulation reliability and scalability for various rotating electrical machine designs.
Implementation Method 1
an adhesive member is applied or attached to inside or on the outside of the insulating tape to be wound, and the insulating tape is wound around a plurality of coil conductors 13 so that overlapped parts of the insulating tape 21 are adhered
Data Source
AI summary
A rotating electrical machine includes a plurality of coil conductors, and an insulating tape. The insulating tape is wound around the coil conductors a plurality of times to form an insulating layer. The insulating layer corresponds to at least a part of the coil conductors protruded from the core is provided so that a part of the wound insulating tape is adhered.