Stator Trickle Impregnation with Inner-Face Temperature Sensing
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Solution Overview
Problem
Existing impregnation devices for electric machine stators face challenges in precise temperature control during the trickle and curing processes, leading to extended production times and increased energy costs due to indirect heating and reliance on winding temperature measurements, which do not accurately represent the temperature of all stator components.
Innovation Solution
The impregnation device incorporates temperature sensors arranged radially inside the stator core and on the drive shaft to measure the temperature on the radial inner face, allowing for precise control of inductive heating and uniform temperature distribution across the stator, with sensors transmitting data wirelessly for real-time control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If heating is performed indirectly through heat transfer between windings and synthetic resin, then the heating process can be simplified, but the heating time is extended and energy consumption increases
Solution Approach 1:
The patent replaces the indirect thermal conduction heating mechanism with direct electromagnetic induction heating. The heating device generates an alternating magnetic field that directly induces eddy currents in the conductive stator components, converting electromagnetic energy directly into heat without requiring thermal transfer through windings and resin. This substitution of heating mechanism dramatically reduces heating time while maintaining process simplicity.
Solution Approach 2:
The heating device operates by applying periodic alternating current to generate oscillating magnetic fields. This periodic electromagnetic action induces continuous eddy currents in the stator components, enabling rapid and uniform heating throughout the impregnation process. The periodic nature of the electromagnetic field allows for efficient energy transfer and controlled heating rates.
2Device complexity
If temperature control is based on winding temperature measurements, then the control system can be simplified, but the temperature representation of all stator components becomes inaccurate
Solution Approach 1:
The patent introduces temperature sensors as intermediary measurement elements that are placed in direct contact with or near the stator core and winding components. These sensors serve as mediators between the heating device and the control system, providing accurate real-time temperature data from multiple locations within the stator assembly. This enables precise monitoring of temperature distribution across different components without complicating the overall control architecture.
Solution Approach 2:
The temperature measurement system is segmented into multiple independent sensors positioned at different locations within the stator (e.g., in the stator core, on the drive shaft, near winding ends). This segmentation allows each sensor to independently measure the temperature of specific components, providing a comprehensive and accurate temperature profile of the entire stator assembly rather than relying on a single measurement point.
3Reliability
If the stator is heated uniformly to ensure complete impregnation, then the quality of impregnation is improved, but the heating time and energy consumption increase
Solution Approach 1:
The heating system employs local quality control by positioning temperature sensors at specific locations (stator core, drive shaft, winding ends) and using this localized data to control the induction heating zones. The heating device can apply different power levels to different regions of the stator based on real-time temperature feedback from these localized measurement points, ensuring uniform impregnation quality while minimizing overall energy consumption through targeted heating.
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 solution enables faster and more uniform heating of the stator, reducing production time and energy costs by ensuring all components reach the desired temperature accurately, thereby improving the reliability and efficiency of the impregnation process.
Implementation Method 1
the heating device having at least one electromagnetic inductor which is arranged so as to be movable coaxially or axially parallel to the stator
Implementation Method 2
heating of the stator or armature by means of an electrical heating current passed through the windings of the stator or armature is already known
Implementation Method 3
at least one temperature sensor is arranged radially inside the stator core, by means of which sensor the temperature on the radial inner face of the stator core and/or of the winding can be measured
Implementation Method 4
The synthetic resin penetrates into the spaces between the winding wires and the lamination cores and fills these gaps completely
Implementation Method 5
the synthetic resin penetrates into the spaces between the winding wires and the lamination cores and fills these gaps completely. In a subsequent heating of the stator or armature to a curing temperature of the synthetic resin, this solidifies and becomes a thermoset
Data Source
AI summary
The invention relates to an impregnation device for trickle impregnation of a stator of an electric machine with a synthetic resin which cures under an increase in temperature, the stator having a hollow cylindrical stator core and at least one winding, a drive shaft being arranged coaxially inside the stator and being drivable by a drive motor, at least one holding device being arranged on the drive shaft, by means of which holding device the stator can be detachably connected to the drive shaft.