Rotary Electric Machine Insulation Segmentation
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Solution Overview
Problem
Conventional rotary electric machines face challenges in managing insulating layers for size reduction, high voltage, and high output due to complexity in thickness and material management between slot portions and coil end portions, leading to increased risk of partial discharges.
Innovation Solution
A rotary electric machine design with armature windings arranged such that insulating members are easily disposed between coil ends of different phases, ensuring insulation performance without changing the thickness or material of the insulating coating, using a specific configuration of rectilinear portions and coil ends housed in slots, and employing cylindrical insulating papers to maintain uniform thickness and enhance insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different thicknesses or insulating materials are used in insulating layers between slot portions and coil end portions to suppress partial discharge, then insulation performance is improved, but thickness management becomes difficult and the application process becomes complicated
Solution Approach 1:
The insulating structure is segmented into two functional parts: a base insulating coating applied uniformly to the conductor wire (providing fundamental insulation), and separate insulating members positioned specifically in coil end portions (providing enhanced insulation where needed). This segmentation allows each part to perform its specific function without complicating the overall application process, as the uniform coating can be applied by standard equipment while insulating members are added only where required.
Solution Approach 2:
Instead of varying insulating layer thickness throughout the entire winding, the invention applies enhanced insulation (insulating members) locally only in the coil end portions where partial discharge risks are highest. The slot portions maintain the standard insulating coating thickness. This local quality approach optimizes insulation performance at critical locations without unnecessarily complicating the overall insulating layer management.
2Reliability
If different materials are used in insulating layers between slot portions and coil end portions to suppress partial discharge, then insulation performance is improved, but the application process becomes complicated
Solution Approach 1:
The insulating system is divided into a base insulating coating (applied to all conductor wires uniformly) and separate insulating members (placed in coil end portions). This segmentation allows the coating process to remain simple and standardized, while material enhancement is achieved through the addition of discrete insulating members rather than complex variable-material application processes.
Solution Approach 2:
The insulating members act as intermediary elements that provide enhanced insulation in critical areas without requiring changes to the base insulating coating process. These intermediaries can be pre-formed components with appropriate materials, simplifying the overall manufacturing process compared to attempting to apply different materials directly to different regions during the winding process.
3Reliability
If insulating layers are made thicker to ensure insulation at high voltage, then insulation performance is improved, but device size increases
Solution Approach 1:
Enhanced insulation is applied locally only in the coil end portions where partial discharge risks and voltage stresses are highest, rather than uniformly throughout the entire winding. This allows the device to achieve the necessary insulation performance for high voltage operation without proportionally increasing the overall device volume, as the slot portions maintain standard insulation thickness.
Solution Approach 2:
The insulating structure is segmented into a base insulating coating of standard thickness and additional insulating members positioned only where required. This segmentation allows the device to achieve enhanced insulation performance in critical areas without uniformly increasing insulation thickness throughout, thereby avoiding proportional increases in overall device size.
Data Source
AI summary
Four layers of first coil rows formed by arranging first coil ends at a pitch of one slot in a circumferential direction are arranged in a radial direction to configure a first coil end group, three layers of second coil rows formed by arranging second coil ends at a pitch of one slot in a circumferential direction are arranged in a radial direction to configure a first coil end group, a cylindrical first insulating paper is housed inside the first coil end rows and inside the second coil end rows, and a cylindrical second insulating paper is housed between the first coil end rows and between the second coil end rows.