Stator Coil Coat-Removed Portions for Coil End Heat Dissipation
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Solution Overview
Problem
Existing stator coils in rotating electric machines have limited cooling performance, which hinders the improvement of output and efficiency due to insufficient heat dissipation at the coil end parts.
Innovation Solution
The stator coil design includes exposed and covered portions of electrical conductor wires, with coat-removed portions on the opposite side of the stator core in the axial direction, and a resin encapsulating member with higher thermal conductivity to enhance heat dissipation and cooling performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the stator coil is cooled by cooling the coil end parts, then the heat dissipation performance is improved, but the temperature increase suppression is insufficient
Solution Approach 1:
The patent applies local quality by creating coat-removed portions at specific locations on the electrical conductor wires where cooling is most needed. The insulating coat is selectively removed only at certain portions of the coil end parts, allowing heat to be dissipated from these localized areas while maintaining insulation elsewhere. This resolves the contradiction by improving heat dissipation performance through targeted local modifications rather than requiring complete insulation removal.
Solution Approach 2:
The patent segments the insulating coat into different portions - some areas maintain the insulating coat while other areas have coat-removed portions. This segmentation allows the coil end parts to have both insulating properties (where the coat remains) and heat dissipation capabilities (where the coat is removed), thereby improving overall heat dissipation performance while maintaining necessary electrical insulation.
2Loss of energy
If the insulating coat is completely removed to improve heat dissipation, then the cooling performance is enhanced, but the electrical insulation is compromised
Solution Approach 1:
The patent applies local quality by creating coat-removed portions at specific locations on the electrical conductor wires where cooling is most needed. The insulating coat is selectively removed only at certain portions of the coil end parts, allowing heat to be dissipated from these localized areas while maintaining insulation elsewhere. This resolves the contradiction by improving heat dissipation performance through targeted local modifications rather than requiring complete insulation removal.
Solution Approach 2:
The patent segments the insulating coat into different portions - some areas maintain the insulating coat while other areas have coat-removed portions. This segmentation allows the coil end parts to have both insulating properties (where the coat remains) and heat dissipation capabilities (where the coat is removed), thereby improving overall heat dissipation performance while maintaining necessary electrical insulation.
3Ease of manufacture
If conventional cooling methods are used for the stator coil, then the manufacturing process is simple, but the cooling performance is limited
Solution Approach 1:
The patent applies preliminary action by forming the coat-removed portions during the laser welding process itself. The laser beam used to weld the electrical conductor wires at the coil end parts simultaneously creates the coat-removed portions by removing the insulating coat in those areas. This preliminary action during manufacturing improves cooling performance without requiring additional manufacturing steps, thus maintaining manufacturing process simplicity.
Solution Approach 2:
The patent merges two functions into one manufacturing step: the laser welding of electrical conductor wires and the formation of coat-removed portions for heat dissipation. By combining these operations, the patent improves cooling performance while avoiding additional manufacturing complexity, as the same laser beam performs both welding and insulating coat removal.
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
The design improves heat dissipation and cooling performance at the coil end parts, effectively suppressing temperature increases and enhancing the overall efficiency of the stator.
Implementation Method 1
a welding step of laser-welding each corresponding pair of the exposed portions of the electrical conductor wires by irradiating a laser beam in a laser irradiation direction to an overlap part between the pair of the exposed portions
Implementation Method 2
a coat-removed portion is formed by heat of the laser beam in at least one electrical conductor wire arranged behind the pair of the exposed portions in the laser irradiation direction
Data Source
AI summary
A stator has a stator coil provided on an annular stator core. The stator coil is formed of electrical conductor wires each including an electrical conductor and an insulating coat. Each of the electrical conductor wires has a pair of exposed portions where the electrical conductor is exposed from the insulating coat and a covered portion where the electrical conductor is covered with the insulating coat. The pair of exposed portions are formed respectively at opposite end portions of the electrical conductor wire. The covered portion is formed at other portions of the electrical conductor wire than the end portions. At a coil end part of the stator coil, each corresponding pair of the exposed portions of the electrical conductor wires are welded together and each of the covered portions of the electrical conductor wires includes a coat-removed portion where the insulating coat is locally removed from the covered portion.