Stator Bonded Ends Radial Arrangement Insulation Cap
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Solution Overview
Problem
Existing stator designs for rotating electrical machines face challenges in ensuring reliable electrical insulation between bonded ends, particularly due to the complexity and inefficiency of pretreatment processes required for coating methods like spray coating and fluidized bed coating, which struggle to effectively fill spaces between bonded ends.
Innovation Solution
A stator design featuring a tubular core with a coil where bonded ends are arranged in a radial pattern and covered by a cap formed through molding using a resin material, reducing the need for pretreatment and enhancing insulation by integrating a groove structure that increases creepage distance and resistance to pullout forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spray coating or fluidized bed coating is used to apply insulating resin to bonded ends, then electrical insulation can be achieved, but pretreatment processes (masking, preheating, viscosity adjustment) are required and it is difficult to satisfactorily fill the space between adjacent bonded ends
Solution Approach 1:
The insulating resin is pre-formed into a cap member with a predetermined shape that includes recesses matching the bonded end configuration. This preliminary preparation eliminates the need for complex pretreatment processes during actual application, as the cap member is simply molded and then fitted over the bonded ends.
Solution Approach 2:
The cap member acts as an intermediary component between the bonded ends and the insulation requirement. Instead of directly coating the bonded ends with resin (which requires complex pretreatment), the pre-formed cap member with integrated recesses serves as a mediator that provides insulation while easily accommodating the bonded end geometry.
2Ease of manufacture
If bonded ends are arranged to extend in the axial direction of the core, then connection is achieved, but the overall axial length of the stator increases
Solution Approach 1:
The bonded ends are arranged to extend in the radial direction of the core instead of the axial direction. This dimensional change from axial to radial arrangement reduces the axial length of the stator while maintaining the electrical connection function, as the radial extension utilizes the available radial space more efficiently.
3Reliability
If a cap member covers bonded ends, then electrical insulation is provided, but the cap may come off under vibration unless resistance force is sufficient
Solution Approach 1:
The cap member features localized protrusions that fit into corresponding recesses in the bonded ends. This local quality enhancement at specific contact points creates mechanical interlocking that provides sufficient resistance to pullout forces under vibration, while the rest of the cap maintains its insulation function.
Solution Approach 2:
The cap member is designed with a nested structure where protrusions on the cap fit into recesses on the bonded ends, creating a interlocked assembly. This nesting arrangement ensures that the cap remains securely attached to the bonded ends even under vibrational conditions, preventing the cap from coming off while maintaining electrical insulation.
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
This configuration ensures effective electrical insulation between bonded ends, reduces the overall axial length of the stator, and maintains insulation integrity even under vibration, while minimizing the risk of short circuits and void formation.
Implementation Method 1
a cap is formed by molding using a resin material having electrical insulation properties so that the cap integrally covers adjacent ones of the plurality of bonded ends
Data Source
AI summary
A stator for a rotating electrical machine, the stator including a tubular core having a plurality of slots; and a coil mounted in the core, wherein the coil includes a plurality of conductor wires aligned in the slots, each of the conductor wires has ends projecting beyond the slot, a pair of the ends are bonded together to form a bonded end, a plurality of the bonded ends are arranged next to each other in a circumferential direction of the core and are arranged in a radial pattern so as to extend in a radial direction of the core, and a cap is formed by molding using a resin material having electrical insulation properties so that the cap integrally covers adjacent ones of the plurality of bonded ends.