Three Phase Motor Insulation Sheet for Short Circuit Prevention
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Solution Overview
Problem
Three-phase motors in electric power steering systems are prone to electrical short circuits among coils receiving different phases of power, leading to malfunction and potential accidents during vehicle operation.
Innovation Solution
A three-phase motor design incorporating a stator with a hollow base and winding portions, a rotor with magnets, and an insulation sheet between coils to prevent electrical short circuits, along with protruding portions on insulators to secure the insulation sheet and prevent it from entering the gap between the stator and rotor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulation sheet is disposed between winding portions to prevent electrical short circuit, then reliability is improved, but device complexity increases due to additional components and assembly steps
Solution Approach 1:
The insulation sheet is integrated with the base portion through protruding portions that fit into grooves on the winding portions, merging the insulation function with the structural support function of the base portion. This reduces the need for separate insulation components and simplifies assembly.
Solution Approach 2:
The insulation sheet acts as an intermediary component between the winding portions, providing electrical insulation while the protruding portions and grooves serve as mechanical intermediaries to secure the insulation sheet in place, preventing it from moving into the gap between rotor and stator.
2Reliability
If protruding portions are added to insulators to secure the insulation sheet, then reliability is improved by preventing the sheet from entering the rotor-stator gap, but manufacturing complexity increases
Solution Approach 1:
The protruding portions are pre-formed on the insulators during the molding process, and the insulation sheet is pre-positioned on these protruding portions before the entire assembly is placed in the stator. This preliminary positioning ensures correct placement without requiring additional assembly steps.
Solution Approach 2:
The protruding portions change the geometric parameters of the insulator by adding localized extensions that fit into grooves on the winding portions. This geometric modification secures the insulation sheet while maintaining compatibility with standard molding processes.
3Reliability
If winding portions are formed apart from each other, then electrical insulation is improved, but the motor's power density decreases due to reduced coil proximity
Solution Approach 1:
The insulation is achieved not only through spatial separation of winding portions in the radial direction but also through the vertical dimension using the protruding portions of the base portion that extend between the winding portions. This multi-dimensional approach to insulation allows winding portions to be closer together while maintaining electrical isolation.
Solution Approach 2:
A thin insulation sheet is used to provide electrical insulation between the winding portions. This thin film approach minimizes the space required for insulation while maintaining effective electrical isolation, allowing winding portions to be positioned closer together for higher power density.
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
The solution effectively prevents electrical short circuits among coils, ensuring the motor's reliability and safety by maintaining electrical insulation and preventing the insulation sheet from being introduced into the rotor-stator gap during high-speed rotation.
Implementation Method 1
an insulation sheet disposed between the winding portions abutting each other to prevent an electrical short circuit among the coils wound around the winding portions abutting each other
Implementation Method 2
a three phase motor... a stator that includes a base portion having a hollow formed therein and a plurality of winding portions extending from the base portion toward the hollow... a rotor having a plurality of magnets inserted therein and disposed in the hollow apart from ends of the winding portions
Data Source
AI summary
According to an embodiment of the present invention, a three phase motor in which a structure for preventing an electrical short circuit is applied includes a stator including a base portion having a hollow formed therein and a plurality of winding portions extending from the base portion toward the hollow and formed apart a predetermined distance from each other; a rotor having a plurality of magnets inserted therein and disposed in the hollow apart from ends of the winding portions; and an insulation sheet disposed between the winding portions abutting each other to prevent an electrical short circuit among the coils wound around the winding portions abutting each other.