Electric Machine Stator Crossed Winding Adhesive Anchoring
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Solution Overview
Problem
Existing stator designs for electrical machines face challenges in securely fastening phase conductor arrangements due to the risk of connection failure caused by the softening of baked lacquer coatings at operating temperatures, leading to potential detachment of coil windings.
Innovation Solution
The stator design incorporates crossed winding sections in the top layer of coil windings with a baked lacquer coating, creating adhesive-filled gaps for secure anchoring of the phase conductor arrangement, which forms a solid composite that maintains connection even when the lacquer softens, and coil carriers with receptacles support the phase conductor arrangement to set a consistent adhesive gap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a baked lacquer coating is used to connect winding sections, then the coil windings form a solid composite that maintains connection strength, but the connection fails when the lacquer softens at operating temperatures
Solution Approach 1:
The coil winding is segmented into multiple layers with crossed winding sections in the uppermost layer, creating discrete anchoring points for the adhesive rather than relying on a continuous lacquer coating. This segmentation allows the adhesive to mechanically interlock with individual winding sections, maintaining connection reliability even when the baked lacquer softens at operating temperatures.
2Ease of manufacture
If the phase conductor arrangement is glued directly to the coil windings, then the fastening is simplified, but the connection fails when the baked lacquer softens
Solution Approach 1:
The uppermost layer of the coil winding is given a special local quality with crossed winding sections that create adhesive anchoring points. This localized structural modification provides enhanced mechanical interlocking capability exactly where the adhesive needs to attach, while the rest of the coil winding maintains its standard structure. The crossed sections create a locally optimized surface for adhesive bonding that remains reliable at operating temperatures.
3Reliability
If winding gaps are created for adhesive anchoring, then the adhesive can positively connect to the coil winding, but the winding structure becomes more complex
Solution Approach 1:
Instead of creating gaps or cavities in the traditional sense, the invention inverts the approach by using the natural spacing and crossing geometry of the winding sections themselves to create the anchoring features. The crossed winding sections in the uppermost layer naturally form spaces between them that serve as adhesive anchors, eliminating the need for additional gap-creating steps or complex structural modifications.
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 design enhances the secure fastening of phase conductor arrangements, ensuring a reliable connection between the phase conductor and coil windings that withstands operating temperatures without failure, providing a robust and stable electrical machine stator.
Implementation Method 1
the electrical conductor of the coil windings each has a baked lacquer coating
Implementation Method 2
the phase conductor arrangement is glued to coil sides of a plurality of coil windings having crossed winding sections
Implementation Method 3
An anchoring of the adhesive in the uppermost layer or in the two uppermost layers of the respective coil winding is achieved by the crossed winding sections
Data Source
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AI summary
A stator of an electric machine is already known, with stator teeth on which a coil carrier with a coil winding is provided, wherein the coil windings each have an electrical conductor with an electrically insulating coating and are each electrically connected to one of several phase conductors of a phase conductor arrangement. The phase conductor arrangement is supported on the coil carriers. In the stator according to the invention, the fastening of the phase conductor arrangement is improved or simplified.According to the invention, it is provided that the electrical conductor (5) of the coil windings (4) each has a baking lacquer coating (11), that coil windings (4) are provided which have crossed winding sections (15) in the uppermost position on their coil side (12) facing the phase conductor arrangement (10), and that the phase conductor arrangement (10) is glued to coil sides (12) of several coil windings (4) having crossed winding sections (15).