Freeform Insulating Separating Element for Electric Machine Windings
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Solution Overview
Problem
Existing winding arrangements for electrical machines face challenges in ensuring process-reliable insulation and reducing the structural height of the winding, while also automating the manufacturing process, as they often result in large air gaps and mechanical stress due to the use of three-dimensional insulating elements with rigid structures.
Innovation Solution
The use of preformed free-form surface separating elements, manufactured using three-dimensional scanning and injection molding or deep-drawing techniques, which form an exact negative image of the winding layers, allowing for gap-free assembly and reduced mechanical stress, enabling automated and efficient winding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If three-dimensional insulating elements with rigid structures are used, then insulation is provided, but large air gaps and mechanical stress occur
Solution Approach 1:
The patent uses a flexible separating element made of a flexible foam material that can deform to conform to the winding layer contours. This flexible membrane structure eliminates air gaps while accommodating mechanical stress, resolving the contradiction between providing reliable insulation and avoiding harmful air gaps and stress concentrations.
Solution Approach 2:
The patent changes the physical state and properties of the insulating material by using a foam material with specific density and elasticity parameters. The foam's cellular structure provides both insulation and flexibility, allowing the material to adapt its shape and absorb mechanical stress while maintaining insulation reliability.
2Reliability
If three-dimensional insulating elements are used, then insulation is achieved, but the structural height increases
Solution Approach 1:
The flexible foam separating element is designed as a thin film structure that provides insulation without adding significant height. The flexibility allows it to conform to the winding layers in a compact manner, maintaining insulation effectiveness while minimizing the axial height of the winding structure.
3Reliability
If complex two-dimensional insulating elements are used, then insulation is provided, but manufacturing automation becomes difficult
Solution Approach 1:
The separating element is created as a negative impression or copy of the winding layer surface geometry. This copying approach allows the complex contoured shape to be reproduced automatically through molding processes, enabling manufacturing automation while maintaining the precise fit needed for effective insulation.
Solution Approach 2:
The separating element is pre-formed with the exact negative geometry of the winding layer before assembly. This preliminary shaping action allows the element to be prepared in advance using automated molding processes, eliminating the need for complex on-site assembly operations and enabling full manufacturing automation.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a winding arrangement (7) for an electric machine, such as an electric motor or generator, comprised of a metallic winding core (8) designed in particular as a laminated core, and also of windings (6) running through grooves (9) of the winding core (8) and each forming a winding head (10) outside of the grooves (9) on end faces of the winding core (8), wherein the windings (6) form in the region of each winding head (10) at least two winding layers (A, B) placed one above the other, between said layers there is arranged an essentially disk-shaped separating element (1) consisting of an electrically insulating material and resting against the windings (6) essentially with no gap. In order to ensure a dependable insulation for the winding layers (A, B) but also an improved automatic winding process and in particular a reduced height of the winding head, the invention proposes that the underside (5) of the separating element (1) be formed by a preshaped freeform surface which is an exact negative image of the winding layer (A) resting below the separating element (1).