Insulating Spacer Aligns Stator Conductors
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Solution Overview
Problem
During the manufacturing of electric machines, conductors in the stator assembly are prone to damage due to bends and twists, which can lead to insulation failure and short circuits, particularly in the outer surface insulation of the conductors.
Innovation Solution
A spacer made of electrically non-conductive material is used to support and insulate conductors in the stator assembly, featuring positioning elements that align and secure short conductors, crossover conductors, and terminal phase lead conductors, preventing electrical contact and facilitating the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conductors are bent and twisted to optimize routing within the stator, then the routing is optimized, but the insulation on the outer surface of the conductors is damaged
Solution Approach 1:
The spacer is positioned and secured to the stator core before the conductors are fully installed and connected. This preliminary positioning establishes the correct routing paths and spacing for the conductors, allowing them to be bent and twisted into place without compromising insulation, since the spacer is already in position to guide and support them.
Solution Approach 2:
The spacer acts as an intermediary component between the stator core and the conductors. It provides a mechanical interface that guides conductor placement, maintains proper spacing, and protects insulation during the assembly process. The spacer's positioning elements and engagement features mediate the interaction between conductors and the stator core, enabling routing optimization without direct contact that could damage insulation.
2Productivity
If multiple conductors are closely positioned to increase winding density, then the winding efficiency is improved, but the risk of electrical contact and short circuits increases
Solution Approach 1:
The spacer provides localized electrical insulation at critical points where conductors are positioned in close proximity. Rather than requiring insulation on every conductor surface, the spacer's positioning elements and engagement features create isolated insulation zones at specific locations where electrical contact risk is highest, allowing high winding density while maintaining reliability.
Solution Approach 2:
The spacer serves as an intermediary insulating barrier between adjacent conductors. Its positioning elements engage with multiple conductors simultaneously, maintaining precise spacing and preventing electrical contact. This mediator approach allows conductors to be densely packed while the spacer ensures electrical isolation, resolving the contradiction between winding density and insulation reliability.
3Reliability
If extensive insulation is applied to each conductor to prevent damage, then the insulation protection is improved, but the assembly complexity and manufacturing time increase
Solution Approach 1:
The spacer combines multiple functions into a single component: it provides structural support, maintains positioning, ensures electrical insulation, and facilitates assembly. By merging these functions, the need for separate extensive insulation layers on each conductor is reduced, as the spacer itself provides the necessary insulation and protection, simplifying both the conductor design and the overall assembly process.
Solution Approach 2:
The spacer is a multi-functional component that simultaneously provides mechanical support, electrical insulation, positioning, and protection for multiple conductors. This universal component eliminates the need for separate insulation treatments for each conductor, reducing assembly complexity while maintaining comprehensive protection. The spacer's engagement features and insulating body work together to protect conductors without requiring complex individual insulation processes.
Data Source
AI summary
A spacer for supporting conductors in a stator assembly of an electric machine includes a plurality of positioning elements cooperating with various conductors in the specials region of the winding arrangement. The spacer illustratively includes an insulating body formed of an electrically non-conductive material and including surfaces facing axially inwardly for contacting short conductors and crossover pockets for receiving crossover conductors which electrically connect an inner winding set and an outer winding set. The spacer further illustratively includes phase lead pockets facing axially outwardly for receiving a terminal phase lead conductor.