Segmented Slotless Stator Windings for Insulation Alignment
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Solution Overview
Problem
Existing slotless electric motors face challenges in insulation application due to complex winding geometries, leading to air bubbles, voids, and dimensional variations, which compromise insulation integrity and alignment, resulting in fitment difficulties and increased weight.
Innovation Solution
A segmented winding assembly with integrated chambers and alignment features, such as channels and interlocks, ensures mechanical alignment and consistent orientation of winding modules, enhancing insulation quality and reducing misalignments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If form-wound windings are used to achieve high power density, then power density is improved, but insulation application becomes difficult due to complex geometries leading to air bubbles and voids
Solution Approach 1:
The stator is divided into multiple independent winding modules, each containing a form-wound winding assembly with its own insulation system. This segmentation allows each module to be insulated separately, avoiding the complex geometry problems of traditional continuous form-wound windings while maintaining high power density through efficient space utilization.
Solution Approach 2:
An insulating resin is used as an intermediary material to encapsulate the form-wound windings within each module. The resin fills all complex geometric spaces uniformly, eliminating air bubbles and voids that would compromise insulation integrity, while the segmented module structure allows controlled application of the resin.
2Reliability
If manual resin application is used to insulate windings, then insulation coverage is improved, but air bubbles and voids are introduced compromising electrical and thermal performance
Solution Approach 1:
The winding assemblies are pre-formed with standardized geometries before insulation application. This preliminary preparation creates uniform surfaces that facilitate bubble-free resin application, ensuring complete insulation coverage while maintaining thermal conductivity through proper resin selection and application techniques.
3Reliability
If different casting molds are used for different phase windings to achieve proper insulation, then insulation quality is improved, but manufacturing complexity and weight increase
Solution Approach 1:
A single standardized casting mold design is used for all phase windings within each module type. The universal mold accommodates different phase windings through standardized positioning features, simplifying manufacturing while maintaining consistent insulation quality across all phases. The modular approach allows the same mold to be reused for multiple phases.
4Stability of the object's composition
If longer end loops are used to facilitate winding overlap, then winding continuity is improved, but weight and resistive losses increase
Solution Approach 1:
The winding assembly is segmented into discrete modules with standardized end loop lengths. This segmentation eliminates the need for excessively long end loops required in continuous windings, reducing weight and resistive losses while maintaining electrical continuity through standardized connection interfaces between modules.
5Ease of manufacture
If dimensional variations in cast encapsulations are allowed, then manufacturing ease is improved, but alignment accuracy deteriorates leading to fitment difficulties
Solution Approach 1:
The stator is segmented into multiple independent modules that are manufactured separately with standardized dimensions. Each module can be manufactured with relaxed tolerances, yet the overall assembly achieves high precision through standardized interface features that ensure accurate alignment when modules are assembled together.
Solution Approach 2:
While overall module dimensions can have broader tolerances, critical interface surfaces and alignment features have localized precision requirements. This local quality approach allows easy manufacturing of bulk dimensions while ensuring accurate fitment at critical interfaces through targeted precision features.
Data Source
AI summary
A slotless electric motor provides a segmented winding assembly with winding modules attached to each other and attached to a circumferential side wall of a stator body. An interlock system mechanically locates the winding modules in predetermined positions relative to the stator body.