Stator Inter-Coil Insulating Body Groove Insertion
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Solution Overview
Problem
Conventional salient-pole concentrated-winding electric motors face challenges in ensuring a reliable insulated state between stator coils due to difficulties in inserting and holding insulating materials, leading to misalignment or dislodgment, which complicates manufacturing and affects the insulated state.
Innovation Solution
A rotary electric machine stator design featuring a stator core with tubular portions and magnetic pole tooth protrusions, using a coil-core insulating body and inter-coil insulating bodies formed by bending an insulating film with specific groove structures that generate elastic recovery forces to securely hold the insulating bodies within insertion grooves, ensuring a strong and reliable insulated state between stator coils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the dimensions of the flange portion of the insulating material are increased to ensure reliable holding in the gap, then the holding force is improved, but it becomes difficult to insert the flange portion into the gap between the bobbins and stator core main body
Solution Approach 1:
The insulating material is divided into multiple segments: a body portion and a flange portion with an insertion groove. The flange portion is further segmented into first and second inserted portions with different cross-sectional shapes, allowing sequential insertion while maintaining holding force through elastic recovery
Solution Approach 2:
The first inserted portion is inserted into the insertion groove first, then the second inserted portion is inserted into the same groove, creating a nested structure where both portions occupy the same space but provide different functions (initial insertion vs. strong holding)
2Ease of operation
If the dimensions of the flange portion of the insulating material are reduced to make it easy to insert into the gap, then the insertability is improved, but the holding force on the flange portion becomes weak
Solution Approach 1:
Different portions of the insulating material have different local properties: the first inserted portion has a cross-sectional shape suitable for easy insertion, while the second inserted portion has a different cross-sectional shape that generates stronger elastic recovery force for reliable holding, each optimized for its specific function
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
Facilitates easy mounting of inter-coil insulating bodies, enhances holding force, and ensures a more reliable insulated state among stator coils, improving manufacturing efficiency and stability.
Implementation Method 1
the inter-coil insulating body includes a groove inserted portion that generates an elastic force of recovery so as to be held inside the insertion groove by being inserted into the insertion groove
Data Source
AI summary
An insertion groove is disposed on a tubular portion overlapping portion that is overlapped with an inner circumferential surface of a tubular portion of the stator core. Inter-coil insulating bodies that are disposed between a plurality of stator coils include a groove inserted portion. The groove inserted portion includes: a first inserted portion that can be inserted inside the insertion groove when the insulating film is in a bent and folded state; and a second inserted portion that is contiguous to the first inserted portion, a shape of a visible outline of a cross section of the second inserted portion being different than that of the first inserted portion. The second inserted portion generates a stronger elastic force of recovery than the first inserted portion when the groove inserted portion is inserted into the insertion groove.