Stator Coil Insulation via Molded Plastic Partition
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Solution Overview
Problem
The existing methods for insulating coil heads in electrical machines are labor-intensive and prone to quality issues due to manual insertion of insulating papers, which hinders efficient and automatic production.
Innovation Solution
A molded plastic body is used to provide reliable insulation between coil ends, allowing for quick assembly and automatic production by separating coil heads with a ring-shaped partition that can be easily placed and adjusted around the stator body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating papers are inserted by hand between coils, then insulation between coil heads is achieved, but the process becomes labor-intensive and time-consuming
Solution Approach 1:
A molded body made of injection-molded plastic is introduced as an intermediary component between adjacent coils. This molded body integrates the insulating function previously performed by hand-inserted papers, while providing a more reliable and automated solution. The molded body is inserted into the stator slot together with the coil, eliminating the need for separate manual insulation steps.
Solution Approach 2:
The insulation function is merged with the coil assembly process. The molded body is designed to be inserted together with the coil into the stator slot, combining two previously separate operations (coil insertion and insulation placement) into a single automated step, thereby improving productivity without compromising insulation reliability.
2Reliability
If insulating papers are inserted by hand, then insulation is provided, but the process allows slippage and quality problems
Solution Approach 1:
The molded body acts as a stable intermediary structure that prevents slippage. Its rigid plastic construction and precise geometric form ensure that the insulation remains in the correct position between coil heads, eliminating the slippage problems associated with flexible insulating papers.
Solution Approach 2:
The material properties are changed from flexible insulating paper to rigid injection-molded plastic. This parameter change provides dimensional stability and prevents deformation during assembly, ensuring consistent insulation quality without requiring complex control processes.
3Productivity
If molded body is used for insulation, then assembly speed increases and automatic production is enabled, but manufacturing complexity increases
Solution Approach 1:
The stator assembly process is segmented into distinct phases: coil winding, molded body insertion, and final assembly. The molded body is manufactured separately as a discrete component, allowing for specialized injection molding processes while keeping the overall assembly simple and automated.
Solution Approach 2:
The molded body serves multiple functions simultaneously: electrical insulation between adjacent coils, mechanical support for the coil within the stator slot, and positioning element during assembly. This multi-functionality reduces the total number of components needed while maintaining high assembly speed and enabling automatic production.
Data Source
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AI summary
The invention relates to a process for producing a stator for an electric machine, comprising the following steps in the given sequence: Providing a cylindrical stator body having several stator slots, inserting at least one first coil in the stator slots, the first coil having a first coil end on at least one face of the stator body, and inserting the first coil end in at least one molded body for electrically insulating the first coil end.