Stator End Turn Insulation Using Segmented Dielectric Separator
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Solution Overview
Problem
Existing stator assemblies with composite insulating paper face reduced cooling efficiency due to restricted air flow and potential damage during manufacturing, as they compromise both electrical insulation and structural rigidity.
Innovation Solution
A stator assembly utilizing a flexible dielectric sheet with cooling holes and a rigid dielectric separator member, featuring a spike-like design with undulating sidewalls and through holes, to enhance air circulation and maintain structural integrity between phase coils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If composite insulating paper is used between phase coils, then electrical insulation is provided, but cooling efficiency is reduced due to restricted air flow
Solution Approach 1:
The patent uses a porous insulating material (such as porous plastic foam) instead of solid composite paper. This porous structure allows air to flow through the insulation layer while maintaining electrical isolation between phases, thereby resolving the contradiction between insulation reliability and cooling efficiency.
2Reliability
If composite insulating paper is used, then electrical insulation is achieved, but the material may become damaged and dislodged during manufacturing
Solution Approach 1:
The patent employs composite construction by combining the porous insulating material with additional structural elements such as rigid supports or anchoring mechanisms. This composite approach maintains electrical insulation while providing the structural integrity needed to prevent damage during manufacturing and assembly.
3Strength
If rigid dielectric material is used for separator member, then structural rigidity and compactness are improved, but ease of insertion between coils is reduced
Solution Approach 1:
The rigid dielectric separator member is divided into multiple segments or sections. This segmentation allows the separator to be inserted between coils more easily while maintaining overall structural rigidity. The segments can be assembled in place, reducing insertion difficulty while preserving the mechanical strength needed for support.
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
The solution effectively maintains electrical insulation while improving cooling efficiency by allowing better air circulation and preventing damage through enhanced structural support and secure positioning of the separator member.
Implementation Method 1
air flow through the coils may be restricted
Implementation Method 2
provide an insulating barrier between adjacent end turns of the coils of different phases
Implementation Method 3
heat tends to be generated through, amongst other things, resistance in the coils
Data Source
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AI summary
An apparatus and method for providing electrical insulation between adjacent end turns at different phases within a stator assembly. In one embodiment, the invention is directed to a stator assembly comprising: a stator core; at least two coils of different phases wound on the stator core through the slots and having an end turn that extends from the stator core; and one or more rigid separator members positioned between adjacent end turns of the coils.