Stator Bellows Slot Liners for Compact Rotating Electrical Machines
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Solution Overview
Problem
The existing stator designs for rotating electrical machines face challenges in reducing coil ends height without compromising insulation properties, particularly in compact spaces like automobiles.
Innovation Solution
The stator design incorporates a stator coil mounted within slots of a stator iron core, with insulating slot liners and conductive wire materials forming bellows portions to reduce coil ends height while maintaining insulation integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the coil ends height is lowered to reduce stator size, then the stator can be compacted for narrow spaces, but the insulation property of the stator deteriorates
Solution Approach 1:
The slot liner is divided into multiple sections along the axial direction, with each section capable of forming an independent bellows portion. This segmentation allows the insulating structure to adapt to the compressed coil ends while maintaining adequate insulation distance, resolving the contradiction between reduced stator size and maintained insulation property.
Solution Approach 2:
The slot liner incorporates bellows portions that function as flexible insulating structures. These bellows portions can be compressed along with the coil ends while maintaining their insulating function, allowing the stator to be compacted without deteriorating insulation properties. The flexible bellows structure adapts to the reduced height while preserving the necessary insulation distance.
2Volume of moving object
If the coil ends height is reduced to fit narrow spaces, then the stator becomes more compact, but the creepage distance of the stator coil section becomes insufficient
Solution Approach 1:
The bellows portions introduce axial compression capability while preserving radial and circumferential insulation distances. By allowing compression in one dimension (axial height) while maintaining insulation in other dimensions (radial and circumferential directions), the design achieves compact size without sacrificing creepage distance.
Solution Approach 2:
The flexible bellows portions of the slot liner maintain the necessary creepage distance through their structured design. Even when compressed, the bellows portions preserve the insulating path length, ensuring adequate creepage distance is maintained despite the reduced overall height of the coil ends.
Data Source
AI summary
A stator for a rotating electrical machine includes a stator coil, a stator iron core having slots into which the stator coil is mounted, and insulating slot liners inserted into the slots, wherein conductive wire materials constituting the stator coil are inserted into the slot liners, and sections of the slot liners protruding from the slots are each provided with a bellows portion.