Rotary Electric Machine Insulation via Multipurpose Part

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Solution Overview

Problem

Rotating electrical machines for motor vehicles face challenges in electrical insulation between different masses and conductive bars, leading to potential short circuits and increased costs due to existing insulation methods such as using sheaths or increasing machine size by leaving space for insulation.

Innovation Solution

A multi-purpose part is used to electrically isolate the heat sink and brush holder from the bearing in multiple zones, employing sleeves and caps to ensure effective insulation while maintaining machine performance, and is formed from a single, cost-effective thermoplastic material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If sheaths are used to insulate the primary battery ground and secondary battery ground, then electrical insulation is achieved, but the number of parts and assembly steps increase

Engineering Contradiction:

Improveelectrical insulationVSAvoidnumber of parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple insulation functions into a single integrated insulating structure that simultaneously insulates the primary battery ground from the secondary battery ground and isolates conductor bars from the bearing. This merging eliminates the need for separate sheaths and reduces assembly steps while maintaining comprehensive electrical insulation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insulating structure is designed to perform multiple insulation functions simultaneously: it acts as both the ground isolation barrier and the conductor bar protection. This multi-functional design reduces the total number of components needed while achieving all required insulation objectives.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If resin is used to insulate the two masses, then electrical insulation is achieved, but the assembly process becomes complicated

Engineering Contradiction:

Improveelectrical insulationVSAvoidassembly process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent extracts the insulation function from the resin material and implements it through a structured insulating component that provides mechanical support and electrical isolation simultaneously. This eliminates the need for complex resin application processes while maintaining effective insulation between the primary and secondary battery grounds.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If sufficient space is left between the bearing and conductor bars for insulation, then electrical isolation is achieved, but the machine's overall size increases

Engineering Contradiction:

Improveelectrical isolationVSAvoidmachine size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent employs thin insulating barriers and flexible insulating structures that provide effective electrical isolation between the bearing and conductor bars without requiring excessive clearance. These thin film-like insulating layers achieve the necessary dielectric strength while minimizing the space required, thus maintaining compact machine dimensions.

Inventive Principle:

Principle #30Flexible shells and thin films

4Volume of moving object

If conductor bars are positioned close to the bearing, then machine compactness is improved, but the risk of accidental electrical contact increases

Engineering Contradiction:

Improvemachine compactnessVSAvoidrisk of short circuit

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent introduces an intermediary insulating structure positioned between the conductor bars and the bearing that physically separates these components while allowing them to remain in close proximity. This intermediary barrier prevents accidental electrical contact while enabling the compact arrangement of conductor bars near the bearing.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution provides reliable and inexpensive electrical insulation across multiple zones, preventing short circuits and reducing costs by simplifying the assembly process and using a single part for insulation, thus maintaining optimal machine performance.

Implementation Method 1

an electronic assembly, notably a power electronics stage, which generally operates with a second battery

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

heat sink and a power electronic stage mounted on the heat sink

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

the multipurpose part is arranged to electrically isolate the heat sink from the bearing

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentEP3322612B1Rotary electric machine for vehicle

Publication Date: 2022.08.03 VALEO EQUIP ELECTRIC MOTEUR

Figure 1~3
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Figure 6~7

AI summary

The present invention proposes a rotary electric machine (1) for a motor vehicle. Said rotary electric machine (1) includes a bearing (7), an electronic assembly (9) arranged to be assembled with the bearing (7) and to comprise all the power electronics of the rotary electric machine (1); and a versatile part (24) arranged to take part in the assembling of the electronic assembly (9) with the bearing (7) and to provide an electric insulation function between the bearing (7) and the electronic assembly (9) in at least two separate areas.