Magnetic Pole Insulation via Winding Frame Grooves
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Solution Overview
Problem
Conventional magnetic pole configurations for rotary electric machines require costly equipment and complex welding processes, leading to unreliable insulation due to variations in welding conditions, which can result in damaged insulators and compromised insulation reliability.
Innovation Solution
A magnetic pole configuration that simplifies the attachment of insulators and winding frames to the core by using sheet-like insulators inserted into slits of the winding frames, eliminating the need for welding and ensuring stable insulation through a design that facilitates easy insertion and secure fixation, thereby enhancing insulation reliability and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding is used to attach insulating films to insulating winding frames, then the insulating films can be securely fixed, but the manufacturing cost increases due to required welding equipment and process complexity
Solution Approach 1:
The patent replaces the ultrasonic welding process (thermal-mechanical system) with a simple mechanical insertion system. The insulating film is inserted into a groove structure formed on the insulating winding frame, eliminating the need for welding equipment and processes while maintaining secure fixation through the groove geometry itself.
2Reliability
If ultrasonic welding is used to attach insulating films, then fixation is achieved, but the insulating films may be damaged or welding conditions may vary leading to unreliable insulation
Solution Approach 1:
The patent applies preliminary anti-action by designing the groove structure in advance to prevent the harmful effects of welding. The groove geometry is specifically designed to guide and secure the insulating film without subjecting it to the high temperatures and mechanical stresses of ultrasonic welding, thereby preventing film damage and welding-related reliability issues before they can occur.
3Strength
If welding processes are used for attachment, then secure fixation is achieved, but the device complexity and equipment requirements increase
Solution Approach 1:
The patent extracts the welding process entirely from the attachment system. Instead of using complex welding equipment to achieve attachment strength, the design extracts only the essential function of securing the insulating film through a simple groove insertion mechanism, eliminating unnecessary equipment complexity while maintaining sufficient attachment strength for the application.
Data Source
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AI summary
A magnetic pole (50) includes a core (40), winding frames (10), and sheet-like insulators (20). The winding frames (10) are provided to both ends, in a direction (Z) along the central axis, of the core (40), and have thin portions (11A, 12A, 13A) and projections (13B). The thin portions (11A, 12A, 13A) and the projections (13B) extend in a direction (Z) along the central axis. The insulators (20) are provided on both sides in the circumferential direction of a tooth portion (41). Apart of each insulator (20) is held by being sandwiched between the projection (13B) and the thin portion (13A) provided to each winding frame (10).