Interphase Insulation Sheet for Motor Winding Automation
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Solution Overview
Problem
In motor manufacturing, the automatic insertion of windings can cause previously inserted interphase insulation sheets to be dragged and crushed, leading to inadequate insulation between windings, which fails to meet the required insulation specifications.
Innovation Solution
The motor design incorporates an interphase insulation sheet with planar insulating portions, insulating convex portions, and leg portions that protrude from the stator core, allowing the sheet to be securely positioned and preventing it from being dragged by subsequent windings, with specific geometrical features such as wider convex portions and notch portions to reduce the risk of deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If the interphase insulation sheet is inserted in H-shape to fix it immovable, then the insulation sheet can be automatically inserted, but the insulation sheet may be dragged and crushed by subsequent windings
Solution Approach 1:
The interphase insulation sheet is divided into multiple functional parts: insulating portions for electrical isolation, leg portions for positioning in slots, and convex portions for preventing dragging. This segmentation allows each part to perform its specific function, preventing the sheet from being dragged while maintaining automation.
Solution Approach 2:
The leg portions and convex portions are pre-formed on the interphase insulation sheet before insertion. The convex portions protrude in advance to create physical barriers that prevent subsequent windings from dragging the sheet, ensuring the insulation specification is maintained throughout the automated winding insertion process.
2Reliability
If the interphase insulation sheet is made wider to prevent dragging, then the insulation sheet can be secured, but the sheet may interfere with slot insertion
Solution Approach 1:
The interphase insulation sheet has different width characteristics at different locations. The insulating portions have sufficient width to prevent dragging and ensure insulation, while the leg portions are designed with appropriate dimensions to fit within the slots. This local differentiation allows the sheet to be secured against dragging without interfering with slot insertion.
Solution Approach 2:
The convex portions protrude in the radial direction from the insulating portions, creating a three-dimensional structure. This dimensional addition provides anti-dragging functionality without increasing the planar width that would interfere with slot insertion, as the protrusion is in the radial dimension rather than the circumferential dimension.
Data Source
AI summary
A motor includes: a stator core having a plurality of slots; and a winding inserted into the slot as distributed windings of three phases, wherein an interphase insulation sheet is mounted on a coil end of the winding. The interphase insulation sheet includes: planar insulating portions disposed so as to protrude from each of end surfaces of the stator core; a first leg portion and a second leg portion which integrally connect the planar insulating portions at the end surfaces and which are inserted into the slots; insulating convex portions that protrude toward an inner side in a radial direction of the stator core from the planar insulating portion; and a third leg portion that integrally connects the insulating convex portions at the end surfaces and which are inserted into the slot.