Rotary Stator Coil Fixing via Localized Resin for Cooling
Solution Overview
Problem
The existing rotary electric machine stators face challenges in preventing coil movement due to external vibrations or temperature fluctuations while maintaining adequate cooling performance, as the use of resin for fixing coils impairs direct coolant contact and thus reduces cooling efficiency.
Innovation Solution
A rotary electric machine stator design incorporating a stator core with a multi-layer winding coil, a first insulating resin layer between the teeth and the lowest layer coil, and a second insulating resin layer at curved portions, which fixes the coil without covering the entire winding, allowing direct cooling and reducing the amount of resin used.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the coil is covered with resin to prevent movement, then coil stability is improved, but cooling performance deteriorates due to reduced direct coolant contact
Solution Approach 1:
The patent applies resin selectively at specific locations where it is most needed for stability (curved portions and between layers) rather than uniformly covering the entire coil. This localized application maintains coil stability while preserving coolant access to critical heat-generating areas, thus resolving the contradiction between stability and cooling performance.
Solution Approach 2:
The resin coating is segmented into discrete locations (curved portions and inter-layer spaces) rather than forming a continuous covering. This segmentation allows different regions of the coil to have different degrees of resin coverage, enabling simultaneous achievement of mechanical stability and thermal management.
2Stability of the object's composition
If resin is applied to fix the coil, then coil stability is improved, but the amount of resin used increases
Solution Approach 1:
Resin is applied only at specific critical locations (curved portions and between layers) rather than uniformly across the entire coil surface. This localized approach reduces the total volume of resin required while still achieving the necessary mechanical stability to prevent coil movement.
Solution Approach 2:
Instead of applying resin excessively to cover the entire coil, the patent uses partial action by targeting only the most critical areas for stability. This reduces material consumption while maintaining sufficient fixation效果.
3Stability of the object's composition
If resin is applied to fix the coil, then coil stability is improved, but the complexity of the manufacturing process increases
Solution Approach 1:
The resin application process is simplified by focusing on specific locations (curved portions and inter-layer spaces) rather than requiring uniform coverage of the entire coil. This reduces the complexity of the manufacturing process while still achieving the desired stability outcome.
Data Source
AI summary
A rotary electric machine stator includes a stator core, a multi-layer winding coil, a first insulating resin layer, and a second insulating resin layer. The multi-layer winding coil is arranged with a predetermined number of steps in the radial direction of the teeth. Each step of the multi-layer winding coil includes a lowest layer coil of one winding and a surface layer coil of another winding. The first insulating resin layer is arranged between the teeth and the lowest layer coil, or between an insulator that is fixed to the teeth and the lowest layer coil. The second insulating resin layer is arranged locally at curved portions of the multi-layer winding coil that correspond to corner portions of four corners of a rectangular cross-section of the teeth. The second insulating resin layer is arranged extending across a plurality of steps of the multi-layer winding coil.