Stator Common Coating for Abrasion Protection
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Solution Overview
Problem
Stators in electric motors face issues with coil wire abrasion due to dust particles in air cooling and complex, costly manufacturing processes, particularly with hand-loaded pre-wound coils and separate coatings for end windings and stator bodies.
Innovation Solution
A stator design where the stator body and end windings are coated with a continuous layer of impregnating resin, which encloses both components, providing mechanical protection and reducing attack surfaces for dust and conductive debris, and allowing for direct winding and simplified production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air cooling is used for the electric motor, then heat dissipation is achieved, but dust particles in the cooling air cause abrasion of the coil wire
Solution Approach 1:
The patent introduces an intermediary protective layer (insulating varnish or protective coating) between the coil wire and the dust particles in the cooling air. This coating acts as a barrier that prevents direct contact between abrasive dust and the coil wire, while still allowing heat to dissipate through the coated surface.
Solution Approach 2:
The patent applies a thin film coating (insulating varnish or protective coating) over the coil wire and stator body. This flexible thin film provides continuous protection against dust particle abrasion while maintaining the underlying structure's integrity and thermal properties.
2Ease of manufacture
If pre-wound coils are manually inserted into the coil space, then coil installation is completed, but the process is time-consuming and cost-intensive
Solution Approach 1:
The patent applies the protective coating to the stator body and coil wire before final assembly. This preliminary coating action ensures that protection is in place before the coils are installed, eliminating the need for subsequent coating steps and reducing overall manufacturing time and cost.
Solution Approach 2:
The patent combines the coating of the stator body and coil wire into a single unified process step. By coating both components together with the same insulating varnish or protective coating, the manufacturing process is simplified and productivity is increased.
3Reliability
If different coatings are applied to the coil wire and stator body, then specific protection is provided, but the manufacturing process becomes complex
Solution Approach 1:
The patent uses a universal insulating varnish or protective coating that serves multiple functions simultaneously: it provides electrical insulation to prevent short circuits, protects against dust particle abrasion, and creates a continuous protective barrier. This single multi-functional coating replaces the need for multiple specialized coatings.
Solution Approach 2:
The patent applies the same insulating varnish or protective coating uniformly to both the stator body and coil wire. This homogeneous approach ensures consistent protection across all surfaces while simplifying the manufacturing process by eliminating the need for different coating materials and application procedures.
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
This solution effectively protects the coil wire from abrasion, increases magnetic flux and torque, reduces motor size, and simplifies production by combining coating and mechanical stabilization steps, leading to improved performance and efficiency.
Implementation Method 1
the outside of the stator body and at least one end winding are at least partially provided with a common coating
Implementation Method 2
An insulated coil wire or field coils made from such a wire are usually inserted into these coil grooves
Data Source
Figure 1~2
Figure 3
Figure 4~5a
AI summary
The stator (10) has stator main portion having outer side and inner side with coil space for receiving coil wire (20) in form of coil (20a). The coil space has several grooves (14) that are limited by stator wall (12a) and pole horns (16) of the stator. The coil wire in form of coil is inserted into coil space. The coil wire is formed is formed from winding heads (23a,23b). The outer side of the stator main portion and winding heads are provided with a common coating. An independent claim is included for method for manufacturing stator.