Segment Coil Stator Insulation Layout to Prevent Partial Discharge
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Solution Overview
Problem
The existing stator designs face challenges in preventing damage to the insulating film due to bending of the rising portion in segment coils, which can lead to cracks and decreased stator quality. Additionally, extending the peeling length of the peeled portion to prevent damage results in potential partial discharge issues due to intersections with adjacent segment coils, necessitating thicker insulating films that increase stator weight and cost.
Innovation Solution
The proposed stator design incorporates segment coils with inclined and rising portions, where the insulating film is peeled in a specific manner to prevent damage during bending. The peeling length of the first peeled portion facing the circumferential direction is longer than that of the second peeled portion facing the radial direction, which helps in preventing damage and intersection issues while maintaining thin insulating films.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the peeling length of the insulating film is extended to prevent damage during bending, then the insulation film is protected from cracks, but the peeled portion may intersect with adjacent segment coils causing partial discharge
Solution Approach 1:
The insulating film is peeled selectively at different locations: peeled at the circumferential side to prevent bending damage, but not peeled at the radial side to avoid intersection with adjacent coils. This localized differentiation of peeling status resolves the contradiction between protecting the film and avoiding partial discharge.
Solution Approach 2:
The peeling of the insulating film is segmented into two distinct regions: a first peeled portion at the circumferential side and a second peeled portion at the radial side. This segmentation allows each region to serve its specific function - the first portion prevents damage during bending while the second portion maintains insulation to prevent partial discharge.
2Reliability
If the insulating film thickness is increased to prevent partial discharge at intersections, then insulation reliability improves, but stator weight and manufacturing cost increase
Solution Approach 1:
Instead of uniformly increasing insulating film thickness throughout, the invention applies selective peeling only where needed (circumferential side) while maintaining the original thin film thickness at other locations (radial side). This localized approach maintains insulation reliability without the penalty of increased overall weight.
3Reliability
If the insulating film thickness is increased to ensure adequate distance between conductors, then partial discharge is prevented, but manufacturing cost increases
Solution Approach 1:
The insulating film is peeled in advance at the circumferential side before assembly, creating the first peeled portion that prevents bending damage. This preliminary action eliminates the need for thicker films and subsequent cost increases, while still ensuring adequate insulation through the non-peeled radial portions.
Data Source
AI summary
A stator includes a stator core having a plurality of slots, and a plurality of segment coils, each of which has an insulating film, the plurality of segment coils each including an inclined portion and a rising portion. the rising portions that are adjacent to each other in a radial direction of the stator core being joined to each other. Each of the plurality of segment coils includes first peeled portions each in which the insulating film facing the circumferential direction of the stator core is peeled in a lengthwise direction, and second peeled portions each in which the insulating film facing the radial direction of the stator core is peeled in the lengthwise direction, and a peeling length of the first peeled portion is longer than a peeling length of the second peeled portion.