Stator H-Shaped Insulator Axial Insertion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing production methods for stators of dynamoelectric rotary machines are complex and labor-intensive, particularly in ensuring proper positioning and electrical insulation of the winding system, which affects efficiency and torque output.
Innovation Solution
The stator design features teeth with parallel or trapezoidal flanks for easy insertion of coil formers, and an H-shaped insulator with flexible side parts for axial insertion between coil sides, providing electrical insulation and mechanical securing, while reducing cavities to enhance copper fill factor and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional coil positioning methods with intermediate plates and radial flanges are used, then electrical insulation is ensured, but production complexity and labor intensity increase
Solution Approach 1:
The patent removes the intermediate plate component entirely, extracting only the essential function of electrical insulation and mechanical positioning. The radial flanges are eliminated, and their functions are integrated directly into the coil structure, simplifying the overall assembly while maintaining insulation reliability.
Solution Approach 2:
The patent combines the positioning and insulation functions into the coil structure itself. The radial flanges of the coil carrier serve dual purposes: providing mechanical positioning on the tooth and ensuring electrical insulation, thereby eliminating the need for separate intermediate plates and reducing production steps.
2Ease of manufacture
If teeth with parallel flanks are used, then coil insertion is simplified, but mechanical fit and stability may be reduced
Solution Approach 1:
The patent employs flexible side parts on the insulating body that can adapt to the groove bottom geometry. This flexibility allows the insulator to accommodate variations in groove shape while maintaining stable coil positioning, resolving the contradiction between easy insertion and stable fixation.
Solution Approach 2:
The insulating body incorporates flexible side parts that can deform to match the groove bottom contour. This flexibility ensures stable mechanical engagement and coil positioning while maintaining ease of insertion, as the flexible parts adapt to the groove geometry during assembly.
3Reliability
If H-shaped insulator with flexible side parts is used, then electrical insulation and mechanical securing are improved, but manufacturing complexity of the insulator increases
Solution Approach 1:
The insulating body is made from plastic-based insulating materials that inherently provide both electrical insulation and flexible mechanical properties. This single material solution delivers dual functionality without requiring complex assembly of multiple components, simplifying manufacturing while maintaining reliability.
4Productivity
If cavities in the groove are reduced, then copper fill factor and heat dissipation are improved, but the fit of insulating components becomes more difficult
Solution Approach 1:
The flexible side parts of the insulating body can deform to accommodate reduced cavity spaces. This flexibility allows the insulator to be properly fitted even when cavities are minimized, enabling both high copper fill factor and effective heat dissipation without compromising assembly feasibility.
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a stator (2) of a dynamo-electric rotary machine (1) which forms a hollow cylindrical body, wherein correspondingly designed laminations (3) are stacked in the axial direction and form this cylindrical hollow body with a stator bore (9), wherein the cylindrical hollow body has teeth (10) and axially extending grooves (11) in the axial direction, wherein the parallel-flanked or trapezoidal teeth (10) are each surrounded by a coil body (14), wherein the coil body (14) is wound with at least one electrical conductor and forms a coil which is part of a winding system (4) of the stator (2), wherein an insulating body (15) having an H-shaped cross-section is located between adjacent coil sections in a groove (11).