Box-Shaped Insulating Cap for Electric Machine Windings
Solution Overview
Problem
Traditional insulating caps for electric machines have a minimum distance constraint between adjacent caps due to overlapping design elements, limiting design flexibility and voltage upgrade possibilities, and require time-consuming assembly processes.
Innovation Solution
A box-shaped insulating cap with a U-shaped seat formed in one piece, allowing increased distance between caps and simplified assembly by removing specific walls to create open surfaces, which also reduces the need for putty application and overlapping zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional two-element caps with overlapping zones are used, then mechanical fixation and electrical insulation are provided, but the minimum distance between adjacent caps is reduced and design flexibility is limited
Solution Approach 1:
The patent merges the two separate cap elements into a single integrated cap structure. The single cap includes a body portion with a first open surface for receiving the winding end and a conductive element, and a second open surface for receiving the phase connection end, eliminating the need for overlapping zones between separate elements and thereby increasing the minimum distance between adjacent caps while maintaining electrical insulation reliability
2Reliability
If traditional two-element caps are used, then insulation is provided, but assembly time is increased due to complex assembly processes
Solution Approach 1:
The patent combines multiple functions into a single cap element, reducing the number of assembly steps. The single cap structure integrates the housing for winding ends, conductive elements, and phase connections into one piece, eliminating the need to assemble and align multiple separate elements, thereby significantly reducing assembly time while maintaining insulation reliability
3Reliability
If traditional two-element caps with overlapping zones are used, then components are housed and insulated, but the minimum distance between caps is reduced limiting voltage upgrade possibilities
Solution Approach 1:
The patent integrates the housing for winding ends, conductive elements, and phase connections into one piece, eliminating the need for overlapping zones between separate elements. This increases the minimum distance between adjacent caps, allowing for higher voltage capabilities and future upgrade possibilities while maintaining electrical insulation reliability
Data Source
AI summary
The electric machine has a stator with windings connected to phase connections. An insulating cap protects the reciprocally connected portions of the phase connections and windings. The insulating cap has a box-shaped body with an opening for the introduction of a winding within it. The body defines a seat housing the phase connection. The seat is formed in one piece with the body.