Motor Varnish Injection Assembly for Targeted Stator Gap Coating
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Solution Overview
Problem
Existing varnish application methods for electric motors often result in varnish flowing away from intended locations, leading to increased varnish usage and potential disruption of motor operation.
Innovation Solution
A varnish injection system comprising a pair of varnish injection assemblies and a biasing device, which are designed to apply varnish to specific gaps between the stator core and wires, ensuring precise varnish distribution and reducing excess varnish usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If varnish is applied to electric motor components, then protection against corrosion and contaminants is improved, but varnish may flow away from intended location increasing total varnish usage
Solution Approach 1:
The patent applies local quality by using multiple nozzles positioned at specific locations to apply varnish locally to different portions of the stator core and wires. Each nozzle targets a specific gap or component area, ensuring varnish is applied only where needed rather than broadly, thus preventing excess varnish flow while maintaining protective coverage.
Solution Approach 2:
The patent uses an insulating layer with trapezoidal intermediate portions as an intermediary to control varnish flow. These portions act as channels or guides that direct varnish from the nozzles to specific target areas, preventing uncontrolled flow away from intended locations while ensuring adequate penetration to protected components.
2Reliability
If varnish is applied to electric motor components, then protection against corrosion and contaminants is improved, but varnish may flow away disrupting operation of other parts
Solution Approach 1:
By positioning multiple nozzles to target specific gaps and components locally, the patent ensures varnish is applied precisely where protection is needed without overflowing to disrupt other motor parts. The localized application prevents harmful varnish accumulation in areas where it could interfere with motor operation.
Solution Approach 2:
The insulating layer with trapezoidal portions serves as an intermediary that channels varnish flow in controlled paths, preventing uncontrolled spread to areas where varnish could disrupt motor operation. This intermediary structure guides varnish to intended targets while blocking or redirecting flow away from sensitive components.
3Manufacturing precision
If varnish is applied to gaps between stator core and wires, then varnish penetration is improved, but precise positioning of varnish injector is challenging
Solution Approach 1:
The patent segments the varnish injection system into multiple nozzles, each positioned to target specific gaps between the stator core and wires. This segmentation allows each nozzle to focus on a particular area, improving penetration precision without requiring complex positioning mechanisms for a single nozzle, as the distributed nozzle array simplifies the overall positioning task.
Solution Approach 2:
The insulating layer with trapezoidal intermediate portions acts as an intermediary that facilitates varnish delivery to the gaps. These portions create natural channels or pathways that guide varnish from the nozzles into the gaps, improving penetration without requiring extremely precise nozzle positioning, as the intermediary structure compensates for positioning tolerances.
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 system effectively applies varnish to both gaps between the stator core and wires, improving varnish penetration and reducing overall varnish usage, thereby enhancing the operational efficiency and durability of electric motors.
Implementation Method 1
The biasing device connects the pair of varnish injection assemblies and is configured to exert a compressive force urging the pair of varnish injection assemblies toward each other
Implementation Method 2
the injector arms are formed of a resilient material configured to elastically deform upon urging by the biasing device
Data Source
AI summary
A varnish injection system for an electric motor includes a pair of varnish injection assemblies and a biasing device. Each varnish injection assembly includes an injector arm and a varnish injector nozzle attached to the injector arm and operable to provide a varnish to a gap defined between the stator core and one or more wires among the plurality of wires. The biasing device connects the pair of varnish injection assemblies and is configured to exert a compressive force urging the pair of varnish injection assemblies toward each other.