Overlapping Stator Insulators for Partial Discharge Reduction
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Solution Overview
Problem
Concentrated winding motors with split stator cores experience partial discharge issues due to short creepage distances between stator windings and tooth tip parts, and require additional components like connecting pins, which increases complexity and component count.
Innovation Solution
The design incorporates insulators with overlapping flanges and bodies that extend radially, featuring through holes for tooth insertion and recessed parts to restrict winding insulation members, enhancing electrical insulation and reducing component count by eliminating the need for connecting pins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If insulators are mounted on split stator core teeth, then the number of turns of stator windings can be increased, but the creepage distance between windings and tooth tip parts becomes short causing partial discharge
Solution Approach 1:
The insulator design extends in the radial direction with an extended radial part that overlaps with adjacent insulators. This radial extension increases the creepage distance in the radial dimension, solving the partial discharge problem while maintaining the split core structure for high turn count windings.
2Stability of the object's composition
If connecting pins are used to connect adjacent insulators, then structural stability is improved, but the number of components and device complexity increases
Solution Approach 1:
The connecting pin function is merged into the insulator structure itself. The extended radial part of each insulator overlaps with adjacent insulators, creating an integrated connection system that eliminates separate connecting pins while maintaining structural stability.
Solution Approach 2:
The extended radial part of the insulator serves multiple functions: it provides electrical insulation, increases creepage distance, and acts as a connecting element with adjacent insulators. This multi-functionality reduces the need for separate components.
Data Source
AI summary
An electrical insulator assembly includes first insulators (200A) and second insulators (200B) that can be fitted onto teeth (121) of a stator core (110) of an electric motor in an alternating manner. Each of the first insulators has a first flange (210), a second flange (220) and a body (230). Each of the second insulators has a first flange (210), a second flange (400) and a body (230). The second flange of the first insulators has first and second overlapping parts (220E, 220F) on opposite circumferential sides. The second flange of the second insulators has first and second overlapping parts (400E, 400F) on opposite circumferential sides. The first overlapping parts (220E) of the first insulators radially overlap the second overlapping parts (400F) of the second insulators, and the second overlapping parts (220F) of the first insulators radially overlap the first overlapping parts (400E) of the second insulators.