Insulating a stator of an electric motor with insulating assemblies and insulating sheets
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Solution Overview
Problem
Existing motors for electric compressors in eco-friendly vehicles face insulation failure due to displacement of interphase insulation members, leading to degraded insulating properties.
Innovation Solution
The motor design includes a stator with insulation members arranged in a specific configuration, featuring first and second insulation sheets with folded end parts and movement restriction parts, along with electrical insulator assemblies to prevent displacement and enhance insulation, ensuring alignment of winding parts and preventing crossing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the interphase insulation member is arranged radially inward of the first end parts of the slot insulation member, then the interphase insulation member can be positioned between winding parts of different phases, but if the interphase insulation member is displaced, a gap may be generated between the interphase insulation member and the slot insulation member, causing degradation of insulating properties
Solution Approach 1:
The insulation structure is divided into multiple functional segments: slot insulation members (first insulation sheets) that prevent insulation failure between lead wires and stator core, and interphase insulation members (second insulation sheets) that prevent insulation failure between different phases. This segmentation allows each component to perform its specific insulating function independently while maintaining overall system reliability.
Solution Approach 2:
The first end parts of the slot insulation member act as intermediary elements that bridge between the slot insulation member body and the interphase insulation member. By extending radially inward, these end parts provide continuous insulation coverage and prevent gap formation even when the interphase insulation member experiences displacement, thus maintaining insulating properties.
2Reliability
If the first end parts of the slot insulation member extend radially inward to cover the tooth projections, then the slot insulation member can effectively prevent insulation failure, but the structural complexity increases
Solution Approach 1:
The slot insulation member is designed with multi-functionality: the body part provides insulation between the lead wire and stator core, while the first end parts extending radially inward provide both insulation coverage over tooth projections and structural support for positioning the interphase insulation member. This universal design reduces the need for separate components.
Solution Approach 2:
The slot insulation member integrates multiple functions into a single component structure. The body part and first end parts are merged into one continuous insulation member, combining the functions of slot insulation, tooth projection coverage, and interphase insulation positioning, thereby simplifying the overall insulation system.
Data Source
AI summary
A motor includes a stator having a core and a plurality of radially inwardly extending teeth defining slots therebetween. Each tooth has a tip having a pair of circumferentially protruding tooth projections. A first insulation sheet is inserted between each pair of the teeth and has a body part and a pair of first end parts formed by folding both ends of the body part toward each other. A second insulation sheets is arranged between the winding parts of adjacent teeth and has a body part and a pair of second end parts formed by folding both ends of the body part away from each other. The tooth projections, the second end parts and the first end parts are arranged in this order from radially inside to outside and overlap radially.