Stator Attachment Varnish Guide Faces for Rotary Electric Machine
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Solution Overview
Problem
Existing rotary electric machine stator manufacturing processes face challenges in ensuring reliable connection and fixation between segment coils and the stator core, with varnish often flowing outwards, reducing the effectiveness of impregnation and complicating the manufacturing apparatus due to the need for a movable cuff support.
Innovation Solution
The implementation of a stator cuff support with varnish guide faces on an axial end surface of the stator core, which directs varnish towards the stator slots, ensuring proper impregnation and fixation of segment coils, and eliminates the need for a movable cuff support by integrating a nonmagnetic resin-based cuff support that simplifies the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If varnish is dropped from above the stator core, then the stator coil is impregnated with varnish for fixation, but the varnish flows out radially outward through the yoke portion, reducing impregnation effectiveness in slot areas
Solution Approach 1:
The stator attachment acts as an intermediary component between the stator core and the varnish application process. The varnish guide faces on the stator attachment redirect the varnish flow from a radial outward path to an axial inward path toward the stator slots, ensuring proper varnish distribution in the slot areas while preventing radial overflow through the yoke portion.
2Manufacturing precision
If a movable cuff support is used to regulate bending positions of conductor segments, then the segment coil can be properly formed, but the manufacturing apparatus becomes complicated
Solution Approach 1:
Instead of using a movable cuff support that requires complex mechanisms to regulate bending positions, the invention inverts the approach by using a fixed stator attachment with varnish guide faces. The conductor segments are bent to contact the attachment teeth, and the varnish guide faces then guide the varnish flow along the bent segments into the slots, eliminating the need for movable components while maintaining manufacturing precision.
Data Source
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AI summary
A stator includes a stator core (12), a stator attachment and a plurality of segment coils. The stator core (12) has a yoke portion (13), stator teeth (14) and stator slots (15). The stator attachment (40) is placed on an axial end surface of the stator core (12). The stator attachment (40) includes attachment teeth (50), attachment slots (51) and varnish guide faces (43a: 46a, 47a). Each of the attachment slots (51) communicates with an axial open end of each of the stator slots (15). The varnish guide faces (43a: 46a, 47a) approach an axially central side toward an attachment slot side in the radial direction. The segment coils (30) are fixed to the stator core (12) with varnish. Each segment coils (30) includes plurality of conductor segments (31). The conductor segment (31) is bent by making contact with the attachment teeth (50).