Hairpin Stator Insulation Positioning and Thermal Dissipation
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Solution Overview
Problem
Stators with hairpin windings using insulating paper suffer from low positioning accuracy and act as thermal insulators, limiting the efficiency of electrical machines.
Innovation Solution
An insulating device with circumferentially distributed passage openings is used to define the position of hairpin element arrangements within stator slots, eliminating the need for conventional insulating paper and enhancing thermal heat dissipation through a casting compound.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating paper is used to position hairpin element arrangements in stator slots, then electrical insulation is provided, but positioning accuracy is low and thermal heat dissipation is impaired
Solution Approach 1:
The patent removes the insulating paper from the stator slots entirely. Instead, the hairpin element arrangements are positioned directly in the slots using precision fixtures during manufacturing, eliminating the positioning function of insulating paper while maintaining electrical insulation through precise positioning and insulation coatings on the hairpin elements themselves.
Solution Approach 2:
The patent introduces an intermediate positioning fixture or tooling during the assembly process that temporarily holds the hairpin elements in precise positions within the slots. This fixture ensures accurate positioning without requiring insulating paper, and is removed after assembly, allowing direct thermal contact between the hairpin elements and stator core.
2Reliability
If insulating paper is used to position hairpin element arrangements in stator slots, then electrical insulation is provided, but thermal heat dissipation is impaired
Solution Approach 1:
The patent removes the insulating paper that acted as a thermal barrier. By eliminating this thermal insulator, heat generated by the hairpin windings can transfer directly to the stator core, significantly improving thermal heat dissipation while electrical insulation is maintained through alternative means such as precision positioning and insulation coatings.
Solution Approach 2:
The patent converts the previously harmful thermal insulation effect of the insulating paper into a benefit by removing it. The direct thermal contact between hairpin elements and stator core, enabled by eliminating the insulating paper, transforms the stator core into an effective heat sink, improving the overall thermal management of the electrical machine.
3Reliability
If insulating paper is introduced into stator slots to line them completely, then electrical insulation is ensured, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent eliminates the insulating paper lining process entirely. Electrical insulation is achieved through precise positioning of hairpin elements using fixtures during manufacturing, and through insulation coatings applied directly to the hairpin elements, removing the need for separate insulating paper installation steps and reducing manufacturing complexity.
Solution Approach 2:
The patent combines the positioning and insulation functions into a single integrated approach. By using precision fixtures that hold hairpin elements in exact positions during assembly, the need for separate insulating paper installation is eliminated, merging multiple manufacturing steps into one streamlined process.
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 solution improves positioning accuracy and thermal heat dissipation, increasing the efficiency and continuous output of electrical machines by ensuring reliable electrical insulation and direct heat transfer from the hairpin winding to the stator core.
Implementation Method 1
enhancing thermal heat dissipation through a casting compound... direct heat transfer from the hairpin winding to the stator core
Data Source
AI summary
Stator for an electrical machine, comprising a stator core with stator slots which are formed along an axial direction with respect to a center axis of the stator and are arranged in a manner distributed in a circumferential direction with respect to the center axis, a hairpin winding with a large number of hairpin element arrangements which are arranged in the stator slots and each emerge from the end side of the stator core, and at least one insulation apparatus with a body in which a large number of passage openings which are arranged in a manner distributed in the circumferential direction are formed; wherein a respective hairpin element arrangement passes through one of the passage openings and the insulation apparatus specifies a distance of the hairpin element arrangement from an edge of the stator slot which receives the hairpin element arrangement.