Stator Insulating Part Prevents Partial Discharge
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional stator manufacturing processes face challenges in maintaining a consistent distance between welded ends of stator coils to prevent partial discharges, and the use of epoxy coating for insulation is inefficient due to uneven application, reducing operational reliability.
Innovation Solution
A stator design incorporating a dielectric insulating part with multiple openings, formed as a single body, is inserted into the joint portions of the stator coils to maintain a predetermined distance and provide insulation, eliminating the need for epoxy coating by using a dielectric material with a dielectric constant of 3 to 5, such as Polyimide, Polyamideimide, or Polyetheretherketone, which covers both joint and conductor areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If epoxy coating is applied to welded ends of stator coils for insulation, then insulation performance is improved, but manufacturing complexity and time increase due to uneven application difficulties
Solution Approach 1:
The patent extracts the insulation function from the epoxy coating process and integrates it into the insulating part structure itself. The insulating part is designed with protrusions that directly contact and insulate the welded ends, eliminating the need for separate epoxy application while maintaining insulation performance.
Solution Approach 2:
The insulating part serves as an intermediary component between the welded ends of stator coils and the surrounding environment. It provides both mechanical support and electrical insulation through its structural design, replacing the epoxy coating's dual function without requiring chemical application processes.
2Reliability
If epoxy coating is used for insulating stator coil ends, then insulation is provided, but manufacturing time increases due to coating application and curing processes
Solution Approach 1:
The insulating part is pre-formed with integrated insulation structures before assembly. The protrusions and cavities are manufactured in advance, allowing direct insertion and immediate insulation without requiring on-site coating application and curing processes.
Solution Approach 2:
The time-consuming epoxy coating application and curing steps are extracted from the manufacturing process. The insulation function is achieved through the mechanical structure of the insulating part alone, significantly reducing manufacturing cycle time.
3Reliability
If distance between welded ends of stator coils is increased to prevent partial discharge, then insulation performance is improved, but stator space utilization decreases
Solution Approach 1:
The insulating part provides localized insulation precisely where needed at the welded ends of stator coils. The protrusions make contact only at critical insulation points, maintaining distance between welded ends only where necessary to prevent partial discharge while preserving space elsewhere in the stator.
Solution Approach 2:
The insulating part utilizes the radial dimension by extending protrusions toward the center of the stator core. This vertical space utilization allows insulation without increasing the axial or tangential dimensions, maintaining compact stator geometry while providing necessary clearance.
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 effectively prevents partial discharges by maintaining a consistent distance between stator coil ends, enhances insulation performance, and simplifies the manufacturing process by eliminating the need for epoxy coating, thereby improving operational reliability and reducing manufacturing time.
Implementation Method 1
an insulating part made of a dielectric material, formed as a single body, having a plurality of openings, inserted into each of the joint portions through the openings to cover at least respective parts of the joint portions, and configured to provide a distance between neighboring joint portions
Data Source
AI summary
Disclosed herein are a stator and a method for manufacturing the same. The stator according to embodiments of the present disclosure includes an insulating part and a plurality of stator coils each having two ends electrically connected to form one joint portion. The insulating part is configured to cover at least respective parts of the joint portions, and to provide a distance between neighboring joint portions. Accordingly, a partial discharge caused by a surge between the joint portions of the stator coils may be prevented, allowing operational reliability of the stator to be increased.