Pre-Shaped Stator Insulation for Gap-Free Conductor Separation
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Solution Overview
Problem
Existing stator designs for electric rotating machines face challenges with incomplete insulation, conductor-to-conductor contact, and complex, time-consuming manufacturing processes for pre-shaped insulators.
Innovation Solution
A stator design featuring a stator core with axially extending slots, where each conductor is individually wrapped with an insulator forming a one-layer-section and an overlapping section, ensuring complete closure and preventing conductor-to-conductor contact. Additionally, an apparatus and method for preparing pre-shaped insulators involve a bending station with a base station and a stamp member to form insulators with overlapping sections efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulator sheets are used for lining slot walls and providing insulation between conductors, then insulation is provided, but gaps exist between the slot liner and the inner surface of the stator slot or between adjacent conductors
Solution Approach 1:
The insulator is divided into multiple sections: a slot liner portion for lining the slot wall, and multiple conductor insulation portions that wrap around individual conductors. Each portion is independently shaped to fit specific geometries, eliminating gaps between components and ensuring complete insulation coverage throughout the slot assembly.
2Reliability
If insulators with overlapping sections are used to encircle conductors, then complete closure and gap prevention are achieved, but manufacturing becomes complex and time-consuming with multiple folding steps
Solution Approach 1:
The insulator is pre-shaped during manufacturing to include the exact overlapping configuration needed for complete closure. The overlapping conductor insulation portions are formed in advance with precise geometry, eliminating the need for complex folding operations during assembly and significantly improving manufacturing efficiency.
3Reliability
If insulators are pre-shaped from flat sheets with multiple folding steps, then overlapping sections are formed, but manufacturing accuracy and shape precision are reduced
Solution Approach 1:
The manufacturing process transitions from progressive folding of flat sheets to direct forming of the insulator in its final three-dimensional shape with pre-formed overlapping sections. This parameter change in the forming process enables precise control of the insulator geometry and overlapping configurations, significantly improving shaping accuracy.
Data Source
AI summary
The invention relates to a stator (1) which may be used within an electric rotating machine. an apparatus for preparing pre-shaped insulators and a method for preparing a pre-shaped insulator. The stator (1) comprises a stator core (10) which has a plurality of axially extending slots (11) arranged in a circumferential direction (C) of the stator core (10) and at least two conductors (20, 21) arranged along a radial direction (R) of the same slot (11). Each conductor (20, 21) is peripherally wrapped by an individual insulator (30) which extends around the outer circumference (22) of the conductor (20, 21), such that in circumferential direction the insulator (30) comprises a one-layer-section (37) and an overlapping section (31) which extend along the complete axial length (29) of the insulator (30).