Stator End Cap Structure to Prevent Casting Air Bubbles
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Solution Overview
Problem
Conventional stators in electric machines are prone to overheating due to air bubbles formed during casting, which disrupt thermal behavior and reduce power capacity.
Innovation Solution
A stator design featuring a stator core with radially extending teeth, end caps with winding wire supports, and an insulation film that prevents axial loading and deformation, ensuring good thermal coupling and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional casting method is used for stator production, then manufacturing process is simple, but air bubbles form causing overheating and poor thermal behavior
Solution Approach 1:
The insulation film is pre-installed on the stator tooth before winding, creating a barrier that prevents air bubble formation during subsequent casting. This preliminary protective action eliminates the harmful effect of air bubbles while maintaining the simplicity of the casting process.
Solution Approach 2:
The insulation film acts as an intermediary layer between the winding wire and stator tooth, serving dual functions: electrical insulation and air bubble prevention. This mediator allows the casting material to flow properly without trapping air, thus improving thermal behavior without complicating manufacturing.
2Reliability
If insulation film is installed tightly to prevent air bubbles, then thermal behavior improves, but insulation film may deform under axial load
Solution Approach 1:
Projections are designed to extend beyond the insulation film edges, creating a protective cushion that prevents axial loads from being transmitted to the insulation film. This beforehand cushioning protects the insulation film from deformation while maintaining good thermal contact.
Solution Approach 2:
The projections serve as mechanical intermediaries that absorb and distribute axial forces, preventing these forces from reaching the insulation film. This mediator structure maintains both the thermal performance and structural integrity of the insulation film.
3Length of moving object
If end caps are positioned close to stator teeth for compact design, then axial dimensions are reduced, but winding wire may apply force to insulation film edges
Solution Approach 1:
The harmful function of the projection edges applying force to the insulation film is extracted and eliminated by extending the projections beyond the insulation film edges. This allows the projections to serve only as protective elements while the insulation film maintains its position without experiencing damaging axial forces.
Solution Approach 2:
The extended projections act as intermediaries that prevent direct contact between the winding wire and insulation film edges. This mediator structure allows compact positioning of end caps while protecting the insulation film from harmful axial forces.
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 stator achieves improved thermal behavior and power capacity by preventing air bubble formation and ensuring effective heat transfer between the stator winding and core, while maintaining compact dimensions.
Implementation Method 1
an insulation film which extends between one of the projections of the first end cap and the opposite projection of the second end cap and which is arranged between the winding wire and the stator core
Implementation Method 2
improved thermal behavior and power capacity by preventing air bubble formation and ensuring effective heat transfer between the stator winding and core
Data Source
AI summary
A stator comprises a core having teeth, at least a first end cap and second end cap which each have a base and a winding wire support. The end caps are arranged on the same tooth so that the bases are directed toward the front sides of the tooth. The stator also has a winding having at least one winding wire which is wound over the end caps around the tooth. The support has two projections which project at opposite sides over the base. The wire extends over the projections of the first and second end caps. An insulation film comprises front edges and extends between one of the projections of the first end cap and the opposite projection of the second end cap and is arranged between the wire and the tooth. The wire extends over the projections without applying any force action to the front edges of the film.