Electric Machine Winding With Variable Insulation Thickness
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Solution Overview
Problem
Existing armature winding designs in electric machines face challenges in achieving high space factor and increased output due to insufficient insulation distances between conductor portions and the armature core, leading to reduced space efficiency and output limitations.
Innovation Solution
The design features conductor wires with oblong cross sections and insulating coatings of varying thicknesses, where the thickness of the coating on the surface facing the slot depth direction is thinner than that on the surface facing the slot arrangement direction, allowing independent setting of insulation distances and improving space factor without compromising insulation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulating coating on the circular arc-shaped surfaces is made thicker to ensure insulation distance between conductor portion and teeth, then insulation performance is improved, but space factor is reduced
Solution Approach 1:
The insulating coating is designed with different thicknesses for different surfaces of the conductor portion. The coating on the flat surfaces facing the slot depth direction is made thinner (t1) while the coating on the circular arc-shaped surfaces facing the teeth is made thicker (t2). This local differentiation allows each surface to have the appropriate insulation thickness for its specific functional requirement, resolving the contradiction between insulation performance and space factor.
Solution Approach 2:
The insulating coating is segmented into multiple regions with different thickness characteristics. By dividing the coating into a first insulating coating region (thickness t1) on flat surfaces and a second insulating coating region (thickness t2) on circular arc surfaces, the design allows independent optimization of insulation distance for different spatial relationships, enabling both adequate insulation and high space factor.
2Reliability
If additional insulating sheets are added to ensure insulation distance, then insulation performance is improved, but device complexity increases
Solution Approach 1:
The insulating function is merged into the insulating coating that is already applied to the conductor portion for inter-conductor insulation. By designing this existing coating to have different thicknesses in different regions, the coating simultaneously provides both inter-conductor insulation and conductor-to-teeth insulation, eliminating the need for separate insulating sheets and reducing manufacturing complexity.
Solution Approach 2:
The insulating coating is designed to serve multiple functions: it provides insulation between adjacent conductor portions (with thickness t1) and simultaneously provides insulation between the conductor portion and the armature core teeth (with thickness t2). This multi-functionality eliminates the need for additional insulating components, simplifying the overall structure and manufacturing process.
Data Source
AI summary
In the electric machine according to the present invention, conductor wires are housed inside slots so as to be arranged into multiple layers in one column so as to contact each other in a slot depth direction in each column such that a longitudinal direction of a long side of an oblong cross section of a conductor portion faces in the slot depth direction, and a thickness of a portion of an insulating coating that is formed on a surface of the conductor portion that faces in the slot depth direction is thinner than a thickness of a portion of the insulating coating that is formed on a surface of the conductor portion that faces in a direction of slot arrangement.