Covering Element for Electromagnetic Machine Slots

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Solution Overview

Problem

Current electromagnetic machines face challenges in flux linkage between the rotor and stator due to radially enlarged tooth tips, leading to difficulties in inserting stator coils, potential coil damage, and reduced insulation lifetime.

Innovation Solution

A covering element comprising sub-elements made of different materials, arranged circumferentially between adjacent tooth tips, which secures the stator coil and enhances magnetic flux linkage, reducing air gap flux ripples and cogging torque, while allowing easy coil insertion without damaging insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If radially enlarged tooth tips are provided to reduce poor flux linkage, then flux linkage is improved, but coil insertion becomes difficult and insulation may be damaged

Engineering Contradiction:

Improveflux linkageVSAvoidcoil insertion

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The covering element is divided into multiple sub-elements (first sub-element, second sub-element, third sub-element) made of different materials, each serving specific functions. This segmentation allows the covering element to simultaneously provide magnetic flux linkage enhancement while maintaining coil insertion capability and insulation protection.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the covering element have different material properties tailored to local requirements. The first and third sub-elements (magnetic material) are positioned where flux linkage is needed, while the second sub-element (non-magnetic material) is positioned where insulation and coil protection are critical. This local differentiation resolves the contradiction between flux linkage and coil insertion ease.

Inventive Principle:

Principle #3Local quality

2Reliability

If radially enlarged tooth tips are provided to improve flux linkage, then magnetic performance is enhanced, but coil insulation may be damaged during insertion

Engineering Contradiction:

Improveflux linkageVSAvoidinsulation damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The covering element acts as an intermediary component between the radially enlarged tooth tips and the coil. It provides a protective interface that prevents direct contact between the sharp tooth tip edges and the coil insulation, thereby preventing damage while allowing the enlarged tooth tips to maintain their flux linkage benefits.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The covering element is installed beforehand to provide protective cushioning for the coil insulation against the radially enlarged tooth tips. This pre-protection prevents insulation damage before the coil is fully inserted and secured, addressing the harmful effect in advance.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of manufacture

If a conventional single-material covering element is used, then manufacturing is simple, but flux linkage performance is insufficient

Engineering Contradiction:

Improvecovering element manufacturingVSAvoidflux linkage

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The covering element uses composite construction with multiple sub-elements made of different materials (magnetic and non-magnetic materials) arranged in sequence. This composite structure enables the covering element to simultaneously provide magnetic flux linkage enhancement through the magnetic material portions while maintaining mechanical protection and insulation properties through the non-magnetic material portions.

Inventive Principle:

Principle #40Composite materials

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 solution improves the efficiency and performance of electromagnetic machines by maintaining better flux linkage, reducing losses, and extending the payback time, while ensuring the stability and longevity of the insulation.

Implementation Method 1

the first sub-element and the third sub-element are made of a magnetic material or a soft magnetic material... link the magnetic flux from the rotor to the stator

Methodology Applied

Scientific EffectMagnetic flux linkage: Magnetic Field

Implementation Method 2

The second sub-element is made of a non-magnetic material or a soft magnetic material... insulating the grooved portion 881 from the other grooved portion 881

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS11368067B2Covering element for covering a slot between two adjacent tooth tips of an electromagnetic machine

Publication Date: 2022.06.21 SIEMENS GAMESA RENEWABLE ENERGY AS

AI summary

Provided is a covering element for covering a slot between two adjacent teeth of an electromagnetic machine, a stator for an electromagnetic machine and a method of forming a covering element. The covering element comprises a first sub-element and a second sub-element. The first sub-element and the second sub-element are arranged adjacent to each other in a first direction. Further, the second sub-element is made of a different material than the first sub-element.