Pole Tooth Module Insulation Body for Electric Machine
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Solution Overview
Problem
The complexity and high expenditure associated with electrical insulation in electric machines, particularly due to the need for precise fitting of insulation paper or plastic coil formers, and the increased processing required for encapsulation to ensure electrical insulation.
Innovation Solution
A pole tooth module with an insulation body formed from injection-molded plastic that encases the pole tooth, providing electrical insulation and mechanical fixation, while also allowing for thermal connection and reduced installation space through a design featuring a central piece and frame elements that surround the pole tooth and coil, facilitating easy assembly and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation paper is used as slot insulation, then electrical insulation is achieved, but the level of complexity when fitting the insulation is particularly high
Solution Approach 1:
The patent combines the insulation function with the coil former structure into a single integrated component. The coil former is designed with built-in insulation features, eliminating the need for separate insulation paper fitting steps. This merging of functions directly reduces the complexity of the fitting process while maintaining reliable electrical insulation.
Solution Approach 2:
The insulation features are pre-integrated into the coil former structure during manufacturing, before the actual assembly process. The coil former arrives at the assembly stage already equipped with its insulation system, eliminating the need for on-site insulation paper folding and insertion. This preliminary preparation significantly reduces fitting complexity.
2Reliability
If plastic coil formers are used for electrical insulation, then insulation is provided, but increased expenditure on sealing off the encapsulation mold or subsequent processing is required
Solution Approach 1:
The patent employs thin film insulation structures integrated into the coil former design. These thin film solutions require less material and create simpler encapsulation requirements compared to bulk plastic coil formers. The thin film approach reduces the complexity of sealing off encapsulation molds while maintaining effective electrical insulation.
3Reliability
If coils are impregnated, drizzled or encapsulated, then electrical insulation is enhanced, but increased expenditure on sealing off the encapsulation mold or subsequent processing is required
Solution Approach 1:
The patent merges the insulation function into the coil former structure itself, eliminating the need for separate impregnation, drizzling, or encapsulation processes. The insulation is built-in and functional from the start, reducing both the number of processing steps and the complexity of sealing off encapsulation molds.
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
This solution simplifies and enhances electrical insulation, reduces installation space, and improves heat dissipation and mechanical stability, ensuring reliable electrical insulation and thermal connection without additional fixing requirements.
Implementation Method 1
an insulation body (1) which encompasses the pole tooth (7) and is designed to electrically insulate the pole tooth (7) from the coil (30)
Implementation Method 2
The coil (30), which is arranged around the central piece (2), and the pole tooth (7) are thermally operatively connected to one another through the openings (20)
Data Source
AI summary
A pole tooth module for an electric machine is provided. The pole tooth module includes a pole tooth with a pole shoe and a pole head, a coil arranged around a circumferential surface of the pole tooth between the pole shoe and the pole head, and an insulation body enclosing the pole tooth and designed to electrically insulate the pole tooth from the coil. To enclose the pole tooth, the insulation body has a central piece, a first frame element and a second frame element. The central piece is arranged between the coil and the circumferential surface and at least partially surrounds the circumferential surface of the pole tooth. The first frame element adjoins a side of the central piece, which side faces the pole head. The second frame element adjoins an opposite side of the central piece, which opposite side faces the pole shoe, and encloses the pole shoe.