End Turn Phase Insulator Lead Wire Restraining Tab

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Solution Overview

Problem

Existing dynamoelectric devices face issues with lead wire migration due to vibrations, which can cause short circuits when lead wires contact the rotor or other moving parts, and prior solutions like zip ties or separate flap mechanisms are costly, complex, and ineffective in preventing radial inward migration or interfering with assembly.

Innovation Solution

Incorporating a lead wire restraining tab as part of an end turn phase insulator that wraps over the lead wires and is laced between windings to prevent radial migration into the stator core and interference with housing components during assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If zip ties are used to restrain lead wires, then lead wire migration is reduced, but the device becomes susceptible to breakdown in certain environments such as refrigerants or oils

Engineering Contradiction:

Improvelead wire migration preventionVSAvoidenvironmental susceptibility

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces durable but environmentally vulnerable zip ties with a lead wire restraining tab made from the end turn phase insulator material. This tab is designed to be integrated into the stator assembly and provides reliable lead wire restraint without the environmental susceptibility of zip ties. The tab effectively serves as a permanent, environment-resistant restraint mechanism.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If a separate flap mechanism is used to restrain lead wires, then lead wire migration is reduced, but device complexity and assembly cost increase

Engineering Contradiction:

Improvelead wire migration preventionVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the lead wire restraining function with the end turn phase insulator by forming a restraining tab directly from the insulator material. This eliminates the need for a separate flap mechanism and reduces assembly complexity. The tab is integrated into the insulator structure and becomes part of the standard stator assembly process, removing the need for additional components and assembly steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The end turn phase insulator is given multiple functions: it provides electrical insulation between phases and simultaneously serves as the basis for the lead wire restraining tab. This multi-functional design eliminates the need for separate restraint components and integrates the restraint function into the existing insulator structure.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If a separate flap mechanism is used to restrain lead wires, then lead wire migration is reduced, but manufacturing cost increases

Engineering Contradiction:

Improvelead wire migration preventionVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines the lead wire restraining function with the end turn phase insulator manufacturing process. The restraining tab is formed from the same insulator material using the same manufacturing processes, eliminating the need for separate restraint components and reducing overall manufacturing cost.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The end turn phase insulator serves dual purposes: providing electrical insulation and forming the lead wire restraining tab. This multi-functionality eliminates the need for additional restraint components, reducing part count, assembly complexity, and manufacturing cost.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Volume of moving object

If lead wires are positioned close to the outer diameter of the stator windings, then space is optimized, but interference with housing shells or other components occurs during assembly

Engineering Contradiction:

Improvespace utilizationVSAvoidassembly interference

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The lead wire restraining tab acts as an intermediary barrier between the lead wires and the stator bore. By positioning the tab radially outward from the windings, it creates a physical barrier that prevents lead wires from migrating inward toward the rotor while also preventing outward migration that would cause interference with housing shells during assembly.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS8125115B2End turn phase insulator with a lead wire restraining tab and method of restraining lead wires on dynamoelectric devices

Publication Date: 2012.02.28 COPELAND SCROLL COMPRESSORS LP

AI summary

A stator comprises a core, a plurality of wire coils, an end turn phase insulator, and at least one lead wire. The wire coils are wound through the slots of the stator and form end turns as they wind from slot to slot. The end turn phase insulator comprises an end turn separating portion and a lead wire restraining tab. The end turn separating portion is sandwiched radially between an inner end turn and an outer end turn. The lead wire restraining tab extends from the end turn separating portion and is partially wrapped over the outer end turn in a manner sandwiching the lead wire between the lead wire restraining tab and the outer end turn. This prevents the lead wire from migrating into the core of the stator.