Foldable Stator Insulation Assembly for More Copper Winding Space
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Solution Overview
Problem
Existing electric machine stators face challenges with insulation papers and caps that require large dimensions and wide tolerances, leading to inefficiencies and potential insulation faults due to complex coupling operations.
Innovation Solution
The use of plastic caps with interference coupling to teeth and foldable insulation sheets that are positioned after cap fixation, allowing for simpler and more precise assembly, reducing cap dimensions and improving insulation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large-sized caps with wide tolerances are used to lock insulation papers, then the insulation papers can be securely positioned, but the overall size of the caps increases and the space for copper windings is reduced
Solution Approach 1:
The cap is divided into two functional parts: a locking portion with axial projections that engages the insulation paper, and a covering portion that provides electrical insulation. This segmentation allows each part to be optimized independently - the locking portion can be small and precise while the covering portion provides the necessary insulation volume
Solution Approach 2:
Different regions of the cap have different functions and dimensions. The axial projections in the locking portion are precisely dimensioned to engage the insulation paper edge, while the covering portion has larger dimensions to provide electrical insulation. This local differentiation allows the cap to be small where precision is needed while maintaining adequate size where insulation is required
2Manufacturing precision
If complex operations are performed to couple caps to teeth axial ends, then the insulation paper positioning precision is improved, but the production time and manufacturing complexity increase
Solution Approach 1:
The insulation paper is pre-positioned against the tooth side surface before the cap is installed. The cap is then simply snapped onto the tooth, and its axial projections automatically engage the pre-positioned insulation paper edge. This eliminates the need for complex operations to position the insulation paper after cap installation
Solution Approach 2:
The cap's axial projections automatically engage the insulation paper edge when the cap is installed on the tooth. The structure itself performs the positioning function without requiring additional operations or tools, simplifying the manufacturing process while maintaining precision
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
This approach enables easier and faster assembly, reduces production time, and increases the volume available for copper windings, enhancing the electric machine's efficiency by allowing for smaller cap tolerances and improved insulation.
Implementation Method 1
The attachment portion (16) of each cap (14) is interposed between the end (3a) of the tooth (3) and the corresponding portions (30) of the sheets (29)
Data Source
AI summary
An electric machine stator has a core of ferromagnetic material, consisting of teeth arranged around a longitudinal axis and defining a plurality of slots; the stator has, for each tooth, an insulating cap fixed to a longitudinal end thereof via an interference coupling and provided with front projections, spaced apart from one another in a radial direction; the windings, which are made of electrically conductive material, extend in the half-slots on opposite sides of each tooth and around the cap, and radially between the front projections; each half-slot carries at least one sheet of foldable insulating material, which has a C-shaped portion, interposed between the first wire portions and the tooth, and at least one flap, longitudinally projecting from the C-shaped portion out of the corresponding half-slot and radially resting on an end portion of one of the front projections.