Elastic Spacer for Winding Head Insulation
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Solution Overview
Problem
The manufacturing process for electric motors, particularly the mechanical stabilization and electrical insulation of end windings, is complex due to the difficulty in inserting insulating materials into curved areas and ensuring adequate insulation between winding overhangs and the air gap.
Innovation Solution
A spacer with an elastic nose and a flat, electrically insulating sheet is used, which is pressed into openings formed by winding heads and teeth, providing mechanical stabilization and electrical insulation in a single step, and is designed as an injection-molded polyamide part with a resilient tab and webs to prevent air bubble formation during resin casting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating paper is used to line the spaces between teeth and wrap coils, then electrical insulation is achieved, but the manufacturing process becomes complex and insulating paper is difficult to insert in curved areas
Solution Approach 1:
The invention combines the mechanical stabilization function (spacer) and electrical insulation function (insulating sheet) into a single integrated component. The insulating sheet is formed directly on the spacer body, eliminating the need for separate insulating paper components and their complex installation processes in curved areas.
Solution Approach 2:
The spacer is designed to perform multiple functions simultaneously: it provides mechanical stabilization by centering and fixing the coil, ensures electrical insulation between the winding head and tooth, and also insulates the winding overhang from the air gap. This multi-functional design simplifies the overall manufacturing process.
2Reliability
If winding heads are encased in casting compound for mechanical stabilization and electrical insulation, then insulation is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The insulating sheet is pre-formed on the spacer before the spacer is inserted into the motor assembly. This preliminary formation of the insulating structure eliminates the need for complex post-assembly insulation processes and casting operations.
3Stability of the object's composition
If elastic spacers are pressed into openings to stabilize and insulate winding heads, then mechanical stability and insulation are improved, but insulation in the direction of the air gap is insufficient
Solution Approach 1:
The insulating sheet is specifically positioned and dimensioned to provide targeted electrical insulation in the critical area where the winding overhang faces the air gap. The sheet extends sufficiently far to ensure adequate insulation coverage in this specific direction while maintaining mechanical stability functions.
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 spacer simplifies the production process by achieving mechanical stabilization and electrical insulation of winding overhangs in a single work step, ensuring effective insulation even at the air gap, and is adaptable to different motor geometries without requiring separate spacers for each engine type.
Implementation Method 1
an elastic nose (2) with a free end (3), with which the spacer (1) is later pushed into the end winding of an electric motor
Implementation Method 2
A flat, electrically insulating sheet (4) is formed on an end of the nose (2) opposite the free end (3)
Data Source
Figure 1~4
AI summary
The spacer (1) has an elastic nose (2) having a free end (3). A planar, electrically insulating sheet (4) is integrally formed at an end of the nose located opposite the free end. The free end of the nose tapers. The spacer is arranged as a one-piece, injection-molded section. The spacer is formed of polyamide. The nose includes a projecting, elastic tab (5). The nose includes raised fillets (6,7) and at least one through opening (8). The sheet is thicker in a center region having the nose than in edge regions. The sheet has a steadily decreasing thickness in the edge regions.