Stator Coil Angled Sections for Impregnation Fixing
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Solution Overview
Problem
Existing stator designs for rotary electric machines face challenges in securely fixing the innermost-diameter coil wire due to inadequate impregnation of the impregnating material, leading to reduced fixing strength and potential coil displacement during electromagnetic vibrations.
Innovation Solution
A stator design featuring a ring-shaped stator core with slots and a stator coil where the innermost-diameter coil wire has angled sections to facilitate improved impregnation of the impregnating material from the inner peripheral side, enhancing the material's permeation in the core-axis direction and ensuring secure fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the impregnating material is dripped from the coil end section side, then the impregnation process is simple, but the innermost-diameter-side coil wire cannot be fixed with certainty due to inadequate impregnation
Solution Approach 1:
The patent inverts the conventional impregnation direction by applying the impregnating material from the inner peripheral side of the stator core toward the outer diameter, rather than from the coil end section. This reverse approach allows the material to reach and properly impregnate the innermost-diameter-side coil wire, ensuring adequate fixing strength while maintaining process simplicity.
Solution Approach 2:
The patent changes the impregnation approach from a unidirectional drip method to a multi-dimensional application where the impregnating material is applied from the inner peripheral side and spreads radially outward and axially along the slots, ensuring comprehensive coverage of all coil wires including those on the innermost diameter side.
2Reliability
If the entire work is immersed in impregnating material bath, then all areas are impregnated, but the impregnating material is deposited in areas where it should not be deposited
Solution Approach 1:
The patent applies the impregnating material locally to specific areas where it is needed - the slots containing the coil wires - rather than immersing the entire stator core. The material is applied from the inner peripheral side and confined to the slot regions, ensuring proper impregnation of coil wires while avoiding deposition on the inner peripheral surface of the stator core and other areas where deposition would be harmful.
3Ease of manufacture
If the impregnating material is applied from the inner peripheral side without angled sections, then the application process is simple, but the area wetted by the impregnating material decreases toward the inner diameter side
Solution Approach 1:
The patent introduces angled sections (first and second angle sections) at both ends of the innermost-diameter coil wire that create a curved or angled geometry. This curvature allows the impregnating material applied from the inner peripheral side to flow along the angled surfaces and wet a larger area of the coil wire, including regions that would otherwise be difficult to reach.
Solution Approach 2:
The angled sections are formed on the innermost-diameter coil wire before the impregnation process. This preliminary geometric modification prepares the coil wire surface to better receive and retain the impregnating material, ensuring that the material can flow into and wet the angled regions effectively, thereby increasing the overall wetted area.
4Reliability
If the stator core is rotated during impregnation, then centrifugal force impregnates the back end of slots, but Lorentz force from leakage flux increases electromagnetic vibrations
Solution Approach 1:
The patent forms angled sections on the innermost-diameter coil wire before applying the impregnating material. This preliminary action creates geometric features that enhance material retention and wetting area, allowing effective impregnation without requiring rotation of the stator core, thereby avoiding the generation of Lorentz force from leakage flux during the impregnation process.
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 angled sections allow for wider impregnation and improved fixing of the innermost-diameter coil wire, enhancing vibration resistance and preventing coil displacement, thereby improving the overall performance and reliability of the stator.
Implementation Method 1
improved impregnation by an impregnating material in a core-axis direction
Implementation Method 2
the impregnating material can be applied over a wide area in the core-axis direction of the innermost-diameter coil wire
Data Source
AI summary
A stator includes a ring-shaped stator core having a plurality of slots arranged in a circumferential direction and a stator coil wound around the slots. The stator coil disposed within the slots is fixed by an impregnating material applied from an inner peripheral side of the stator core. An innermost-diameter coil wire of the stator coil positioned on the innermost-diameter side within the slots is provided with a first angle section that is angled towards an outward core-diameter direction side from a center section in a core-axis direction towards one end side, and a second angle section that is angled towards the outward core-diameter direction side from the center section in the core-axis direction towards another end side. The center section in the core-axis direction of the innermost-diameter coil wire projects towards an inward core-diameter direction side.