Stator Coil Apex Overlap for Insulation Reliability
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Solution Overview
Problem
Existing stator coils for rotating electric machines face insulation failures due to reduced insulating coat thickness and interference between crank-shaped parts, leading to insufficient insulation distance and performance degradation.
Innovation Solution
The stator coil design features circumferentially-adjacent turn portions with overlapping apex parts and oblique parts, ensuring axially spaced apex parts and sufficient insulation, while maintaining the benefits of press-shaping for crank-shaped parts, thereby preventing deformation and ensuring reliable electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If press-shaping is used to form crank-shaped parts in turn portions, then manufacturing efficiency is improved, but insulating coat thickness is reduced and insulation reliability deteriorates
Solution Approach 1:
The patent introduces axial positioning as a new dimension to control the spatial relationship between adjacent turn portions. By making apex parts overlap in the axial direction while maintaining circumferential spacing, the invention adds a dimensional constraint that prevents insulating coat deformation during press-shaping, thus maintaining insulation reliability while preserving manufacturing efficiency.
Solution Approach 2:
The overlapping apex parts act as an intermediary structure between adjacent turn portions. This overlapping configuration serves as a buffer zone that prevents direct contact and interference between crank-shaped parts of adjacent turn portions during press-shaping, thereby protecting the insulating coats while allowing efficient manufacturing.
2Device complexity
If crank-shaped parts are formed by press-shaping, then manufacturing complexity is reduced, but insulating coat deformation occurs and insulation distance becomes insufficient
Solution Approach 1:
The patent utilizes the axial dimension to create overlapping apex parts that vertically separate the crank-shaped parts of adjacent turn portions. This dimensional arrangement ensures sufficient insulation distance is maintained even when crank-shaped parts are formed by press-shaping, without requiring complex manufacturing processes.
3Volume of moving object
If adjacent turn portions are positioned close together, then coil end part volume is reduced, but apex parts interfere with each other and insulating coats deform
Solution Approach 1:
The patent resolves the spatial conflict between adjacent turn portions by utilizing the axial dimension. Overlapping apex parts in the axial direction allow close circumferential positioning (reducing coil end part volume) while maintaining insulating coat integrity through vertical separation of crank-shaped parts.
Solution Approach 2:
The overlapping apex parts of adjacent turn portions are positioned in a nested arrangement along the axial direction. This nesting allows the turn portions to occupy overlapping axial spaces without interfering with each other, thereby reducing the overall coil end part volume while protecting insulating coats from deformation.
Data Source
AI summary
A stator includes an annular stator core having slots arranged in a circumferential direction thereof and a stator coil comprised of phase windings. Each of the phase windings includes in-slot portions, each of which is received in one of the slots of the stator core, and turn portions each of winch is located outside the slots to connect one pair of the in-slot portions. Each of the turn portions includes an apex part that is furthest in the turn portion from an axial end face of the stator core and extends in the circumferential direction of the stator core. There are circumferentially-adjacent pairs of the turn portions over the entire circumferential range of the stator coil. For each of the circumferentially-adjacent pairs of the turn portions, the apex parts of the circumferentially-adjacent pair of the turn portions overlap each other in an axial direction of the stator core.