Foldable Interphase Insulator for Electric Machine Stator Slots
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Solution Overview
Problem
Existing interphase insulators in electric machines face challenges in ensuring reliable electrical insulation between coils, particularly when multi-phase coils are inserted, leading to potential contact and deformation issues due to uncontrolled deformation and residual biasing forces.
Innovation Solution
A foldable interphase insulator with longitudinal and head-insulating portions, featuring foldable tabs that align and cover coil heads, preventing electrical contact and facilitating controlled insertion by minimizing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional rigid interphase insulators are used, then electrical insulation between coils is provided, but deformation and residual biasing forces occur during insertion causing unreliable insulation
Solution Approach 1:
The insulator transitions from a rigid structure to a flexible one by incorporating creases that allow controlled deformation during insertion. The flexible nature enables the insulator to adapt to slot variations without generating harmful residual forces, while maintaining electrical insulation functionality throughout the deformation process.
Solution Approach 2:
The insulator's physical state is changed by introducing creases that modify its mechanical properties. These creases allow the insulator to change from a rigid, force-generating structure to a flexible, adaptive structure that can deform controllably during insertion, eliminating residual biasing forces while preserving insulation reliability.
2Shape
If foldable tabs are added to align with coil heads, then neat assembly and contact prevention are improved, but insulator structure complexity increases
Solution Approach 1:
The insulator is segmented into functional zones: the body portion for electrical insulation and the foldable tabs for alignment and contact prevention. This segmentation allows each part to perform its specific function independently, with tabs providing neat assembly through folding actions while the body maintains insulation, thereby managing complexity through functional division.
3Reliability
If insulating material is placed between coils in the same slot, then electrical insulation between phases is ensured, but insertion complexity and potential deformation increase
Solution Approach 1:
Multiple insulation functions are merged into a single integrated component. The insulator simultaneously provides electrical insulation between phases, alignment through foldable tabs, and adaptive deformation capability through creases. This merging eliminates the need for separate insulation layers between coils, simplifying the insertion process while maintaining reliable interphase insulation.
Data Source
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AI summary
Electrically insulating material so foldable as to form an interphase insulator so configured as to be inserted in the slots of the stator or the rotor of an electric machine to prevent separate coils inserted in the same slot to be in direct contact with one another and to prevent the coil heads of different coils to be in direct contact is described herein. The interphase insulator may be so folded that the coil heads are properly insulated from one another.