Dynamo-Electric Machine Insulator with Localized Thickness
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Solution Overview
Problem
In dynamo-electric machines for automobiles, downsizing requires reducing the height of coil ends while maintaining a stable insulation distance, which is challenging due to the limited space and the deterioration of productivity when increasing the thickness of the insulation film to handle surge voltages.
Innovation Solution
A stator with a U-shaped segment coil and an insulator having varying thicknesses, where the insulator's overlapping parts are thicker to enhance insulation reliability and withstand surge voltages, is used to improve the insulation reliability and maintain the required insulation distance in a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of the insulation film is increased to handle surge voltages, then the insulation reliability is improved, but the productivity deteriorates due to formability issues
Solution Approach 1:
The insulator is designed with non-uniform thickness, having a first thickness in regions requiring high insulation (such as where surge voltages occur) and a second, smaller thickness in other regions. This local differentiation allows the insulator to provide enhanced insulation reliability at critical locations while maintaining overall compactness and avoiding the productivity deterioration associated with uniformly thick insulation films throughout the entire coil structure.
2Volume of moving object
If the height of the coil end part is reduced for downsizing, then the space requirement is decreased, but the insulation distance becomes difficult to secure
Solution Approach 1:
The insulator incorporates a first thickness in specific regions where insulation distance is critical and a second, smaller thickness in other regions. This allows the coil end part to maintain a reduced overall height for downsizing purposes while ensuring adequate insulation distance is preserved at critical locations through the strategically positioned thicker portions of the insulator.
Solution Approach 2:
Instead of increasing the height dimension to provide insulation distance, the invention utilizes the radial thickness dimension of the insulator to provide the necessary insulation. This dimensional approach allows adequate insulation distance to be secured without increasing the coil end height, thereby enabling downsizing while maintaining insulation reliability.
Data Source
AI summary
To improve insulation reliability of a dynamo-electric machine. A stator or a dynamo-electric machine using the stator according to the present invention includes a stator iron core in which a plurality of slots aligned in the circumferential direction are formed, a plurality of segment coils inserted into the slots and formed nearly into a U-shape, and an insulator arranged between the segment coils, and the insulator has a part of the insulator formed thicker than the other part of the insulator.