Stator Insulating Sheet Length Optimization for Creepage Distance
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Solution Overview
Problem
In rotary electric machines with concentrated winding and separated iron core structures, excessive insulating sheets are used due to inadequate consideration of creepage distance between windings, leading to increased weight and cost.
Innovation Solution
The insulating sheets are designed with extended portions that only cover the necessary creepage distance between windings, allowing for a minimum length that secures insulation without excess material, featuring mounted and extended portions with ear portions formed on one side to alternately cover the windings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating sheets are extended to cover the entire length of protruded windings, then insulation capability between windings is improved, but weight and cost of the stator increase due to excessive material usage
Solution Approach 1:
The patent changes the length parameter of the insulating sheet from covering the entire winding length to covering only the necessary creepage distance. This parameter optimization ensures sufficient insulation while eliminating excessive material, thereby reducing stator weight and cost without compromising insulation reliability
Solution Approach 2:
The patent extracts only the essential portion of the insulating sheet that is needed for insulation purposes (the creepage distance between windings) and removes the excessive extended portions. This extraction principle allows the insulating sheet to maintain its insulation function while significantly reducing material consumption, weight, and cost
2Reliability
If insulating sheets are extended to cover the entire length of protruded windings, then insulation capability between windings is improved, but cost of the manufactured stator increases due to excessive material usage
Solution Approach 1:
The patent optimizes the length parameter of the insulating sheet to match the actual insulation requirement (creepage distance) rather than using excessive material. This parameter change reduces material costs while maintaining adequate insulation capability, thereby improving manufacturing cost efficiency
Solution Approach 2:
The patent removes the excessive extended portions of the insulating sheet that go beyond the necessary creepage distance. This extraction of unnecessary material directly reduces manufacturing costs while preserving the essential insulation function between windings
3Reliability
If insulating sheets are extended beyond the necessary length, then insulation coverage is improved, but the length of insulating sheets increases leading to material waste
Solution Approach 1:
The patent precisely determines and sets the length parameter of the insulating sheet to correspond exactly to the creepage distance required for insulation between windings. This parameter optimization eliminates both insufficient and excessive length, achieving perfect fit and eliminating material waste
Solution Approach 2:
The patent extracts only the necessary length of the insulating sheet that corresponds to the creepage distance between windings, removing all excessive extended portions. This extraction ensures that the insulating sheet length is minimized while maintaining adequate insulation coverage
Data Source
AI summary
In a concentrated winding stator, which has a separated iron core structure, of a rotary electric machine, a length of ear portions 3c of insulating sheets 3, which are protruded between neighboring winding 4, is set as a length by which a creepage distance, which is required for an insulation between the neighboring windings 4, can be secured.