Stator with Dual Jig Arrangement for Insulation
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Solution Overview
Problem
The downsizing of rotary electric machines has made it challenging to secure adequate insulation between the joining parts of conductor segments in stator coils, particularly due to reduced creepage distances and increased costs associated with post-welding insulation resin application.
Innovation Solution
A stator design where the tip ends of conductor segments in the same phase are bent closer together and those in different phases are bent further apart, utilizing a specialized manufacturing apparatus with jigs to adjust the positions of the conductor segments and segments, allowing for improved insulation properties without the need for additional insulation resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the diameter of the stator core is reduced to downsize the rotary electric machine, then the overall size is reduced, but the creepage distance between joining parts of conductor segments in different phases becomes shorter, making it difficult to secure insulating property
Solution Approach 1:
The patent applies local quality by creating different distance relationships for conductor segments based on their phase relationships. Specifically, the distance between tip ends of conductor segments in different phases is made larger than the distance between tip ends in the same phase. This localized differentiation of spacing ensures adequate insulation where needed (between different phases) while maintaining compact dimensions overall, resolving the contradiction between downsizing and maintaining insulating properties.
2Reliability
If insulation resin is applied to coat the joining parts after welding, then the insulating property is improved, but additional manufacturing steps and materials are required, increasing costs
Solution Approach 1:
The patent applies the self-service principle by designing the conductor segment arrangement to provide its own insulation through proper spatial positioning. The larger distance between tip ends of conductor segments in different phases creates natural insulation clearance, eliminating the need for additional insulation resin coating steps. This self-insulating design reduces manufacturing complexity and costs while maintaining reliable insulation properties.
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 configuration enhances the insulating properties between conductor segments, reduces the requirement for post-welding insulation resin application, and helps in downsizing the stator while maintaining effective insulation, thereby lowering manufacturing costs and improving efficiency.
Implementation Method 1
a jig configured to bend, in a stator-core circumferential direction, conductor segments projecting from stator-core axial end surfaces of slots provided in a stator core
Implementation Method 2
The tip ends (conductor exposed parts) where the insulating coatings are removed are joined to each other by welding by TIG arc welding (Tungsten Inert Gas welding) or laser irradiation
Implementation Method 3
The tip ends (conductor exposed parts) where the insulating coatings are removed are joined to each other by welding by TIG arc welding (Tungsten Inert Gas welding) or laser irradiation
Data Source
AI summary
A stator for a rotary electric machine includes a stator coil configured such that a tip end of a conductor segment bent in a stator circumferential direction is joined to a tip end of another conductor segment in the same phase. A conductive material is exposed from the tip ends of the conductor segments, and a distance between the tip ends in different phases and adjacent to each other in the stator circumferential direction is larger than a distance between the tip ends in the same phase and adjacent to each other in the stator circumferential direction.