Stator Cover Fixation for Insulation and Wire Protection
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Solution Overview
Problem
Existing electric machines face challenges in enhancing the functionality and preventing insulation damage to windings and lead wires due to the lack of effective electrical insulation and mechanical stability between the stator and cover components.
Innovation Solution
A method involving a metallic rough body with grooves and an insulating cover with complementary indentations and fixation elements is used to secure the cover to the rough body, providing electrical insulation and mechanical stability, with conductor wires encased in insulation and twisted to prevent direct bending over sharp edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cover is arranged on a rough body to provide electrical insulation, then electrical insulation is improved, but mechanical stability and positioning accuracy deteriorate due to lack of secure attachment
Solution Approach 1:
Fixation elements act as intermediaries between the cover and rough body, providing both mechanical attachment and positioning functions. These elements transfer forces between components while maintaining precise alignment, resolving the contradiction between electrical insulation reliability and mechanical stability.
Solution Approach 2:
The attachment system is segmented into multiple fixation elements distributed across the cover-rough body interface. This segmentation allows localized positioning and securing functions while maintaining overall mechanical stability and electrical insulation integrity.
2Stability of the object's composition
If fixation elements are added to secure the cover to the rough body, then mechanical stability is improved, but device complexity increases due to additional components
Solution Approach 1:
The fixation elements are designed to perform multiple functions simultaneously: mechanical attachment, positioning alignment, and force distribution. This multi-functionality reduces the need for separate components, thereby improving mechanical stability without proportionally increasing device complexity.
Solution Approach 2:
The positioning and attachment functions are merged into a single integrated fixation element structure. By combining these functions, the design achieves mechanical stability while minimizing the number of discrete components required.
3Ease of operation
If conductor wires are inserted into grooves after cover assembly, then wiring flexibility is improved, but risk of insulation damage increases due to sharp edges and bending
Solution Approach 1:
The grooves are pre-formed with rounded bottom surfaces before wire insertion. This preliminary preparation eliminates sharp edges that could damage insulation, allowing flexible wire routing without increasing damage risk.
Solution Approach 2:
The groove geometry is designed to provide protective cushioning for the conductor wires. The rounded bottom surfaces act as protective features that prevent direct contact between sharp edges and wire insulation, cushioning against potential damage during installation and operation.
Data Source
AI summary
The disclosure relates to a method of providing a component for an electric machine having a body including multiple grooves and multiple indentations, and a cover including multiple recesses and multiple fixation elements. The method includes arranging at least one of the indentations at an edge of each of the grooves of the body, arranging at least one of the fixation elements at each of the recesses, and arranging the cover on the body with each of the recesses of the cover associated with a respective one of the grooves of the body, and each of the fixation elements of the cover arranged in a respective one of the indentations of the grooves of the body.