Hairpin Stator Connection Spacing for Welding-Safe Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing stator designs for rotating electric machines face issues with insulation breakdown and damage to insulating coating films due to excessive proximity of electrically-connected parts and inadequate stripping lengths, leading to compromised insulation performance.
Innovation Solution
The stator design incorporates a structure where electrically-connected parts are spaced to maintain the shortest distances, with predetermined stripping lengths of the insulating coating films to prevent damage and exposure, ensuring secure insulation performance between adjacent parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the insulating coating film is stripped from the end portion of the protruding part for coupling, then the hairpins can be electrically coupled to form coil pairs, but the insulating performance of the electrically-connected part is lowered and vulnerable portions are generated
Solution Approach 1:
The patent applies local quality by differentiating the treatment of insulating coating films at different locations: the film is stripped only at the end portions of protruding parts where electrical coupling is required, while the film is preserved at other locations including adjacent areas. This localized approach enables electrical coupling functionality where needed while maintaining insulation performance where required.
2Reliability
If the stripping length is made short to reduce vulnerable portions, then insulation performance is improved, but the insulating coating films around the electrically-connected part may be damaged due to heat during welding
Solution Approach 1:
The patent applies beforehand cushioning by preserving the insulating coating film in advance at areas adjacent to the electrically-connected parts. This pre-prescribed insulation barrier acts as a protective cushion during the welding process, preventing heat from damaging the insulating coating films while still allowing adequate electrical coupling at the stripped end portions.
3Area of stationary object
If adjacent electrically-connected parts are positioned close to each other, then the stator structure is compact, but the probability of insulation breakdown increases due to excessive proximity
Solution Approach 1:
The patent applies local quality by creating spatial differentiation in the stator core structure: electrically-connected parts are positioned close to each other in the radial direction for compactness, while maintaining adequate spacing in the axial direction through preserved insulating coating films. This localized quality distribution enables compact radial design while preventing insulation breakdown through axial separation.
4Reliability
If the insulating coating film is completely removed for reliable electrical coupling, then electrical connection is improved, but the area of exposed conductor increases and insulation performance deteriorates
Solution Approach 1:
The patent applies partial action by stripping the insulating coating film only to the extent necessary for reliable electrical coupling at the end portions of protruding parts, rather than completely removing it. This partial stripping achieves adequate electrical connection while minimizing the exposed conductor area and preserving insulation performance in non-coupling regions.
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 significantly reduces the probability of insulation breakdown and maintains insulation performance by minimizing vulnerable areas and exposure, while preventing damage to insulating coating films during welding.
Implementation Method 1
An insulating coating film is stripped from an end portion of the protruding part for coupling
Implementation Method 2
The electrically-connected part is formed by heat
Implementation Method 3
the insulating performance of the electrically-connected part is lowered due to the removal of the insulating coating film
Data Source
AI summary
The present disclosure relates to a stator for a rotating electric machine. A plurality of electrically-connected parts is formed on one side surface of a stator core to electrically connect a plurality of hairpins. Among portions of two electrically-connected parts adjacent to each other in a circumferential direction of the stator core, portions located at the same distance from the one side surface of the stator core have shortest distances therebetween, which are set to have difference values included in a preset range value. This may result in preventing a generation of a vulnerable portion at which two adjacent electrically-connected parts are excessively adjacent to each other in the circumferential direction of the stator core.