Two-Part Insulating Retaining Element for Stator Phase Bars
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Solution Overview
Problem
Stator windings of electric motors face high interconnection costs and accessibility issues due to the need for many welds, which are difficult to access and require additional insulation, increasing space requirements.
Innovation Solution
A two-part insulating retaining element for stator windings, comprising a first component with cut-outs for phase potential bars and a second component that forms a trough with the first component, allowing for easy welding and subsequent molding with insulating material, reducing space requirements and improving accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welds are made to connect coil wires to phase potential bars, then electrical interconnection is achieved, but accessibility to welding tools becomes difficult due to low available working space
Solution Approach 1:
The retaining element is divided into two separate components: a upper retaining element and a lower retaining element. These components are positioned at different heights relative to the phase potential bars, creating vertical separation. This segmentation allows welding tools to access the connecting points from above the upper retaining element, solving the accessibility problem while maintaining reliable electrical interconnection.
2Reliability
If insulating material is applied to insulate connecting points and welds, then electrical insulation is achieved, but space requirements increase considerably
Solution Approach 1:
The insulating function is merged with the retaining function by integrating insulating material directly into the retaining elements. The upper and lower retaining elements are positioned close to the phase potential bars and connecting points, providing insulation without requiring separate insulating structures. This merging eliminates the need for additional space-consuming insulating material while ensuring reliable electrical insulation.
Data Source
AI summary
A stator for an electric motor has phase potential bars and an insulating retaining element. The insulating retaining element includes a first component configured to accommodate the phase potential bars and to insulate the phase potential bars electrically from one another. The insulating retaining element additionally includes a second component which is separate from the first component. The second component, in conjunction with the first component, forms a trough that borders on the phase potential bars.