Stator Insulation Plate Groove Design for Laser Welding Heat Protection
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Solution Overview
Problem
Conventional stators for electric rotary machines face issues with insulation damage and reduced insulation performance due to heat application during the joining of connection coils and slot coils, particularly when using insulation plates that abut the joining portions.
Innovation Solution
A stator design featuring slot coils and connection coils with abutment portions accommodated in insulation plates, where the connection coils are spaced apart from the insulation plate in a circumferential direction to form gaps, allowing for heat application without damaging the insulation plate, and utilizing a method that includes surface contact pressure and laser welding for joining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the insulation plate abuts against the joining portion where connection coils and slot coils are connected together, then the insulation plate provides structural support and positioning, but heat damage to the insulation plate occurs during joining operations
Solution Approach 1:
A groove structure is introduced as an intermediary element between the insulation plate and the joining portion. The groove allows the connection coil to be accommodated while maintaining a gap between the coil and the insulation plate, thereby mediating the thermal interaction and protecting the insulation plate from heat damage during joining operations.
Solution Approach 2:
The insulation plate is segmented by introducing grooves that create distinct regions. The groove structure divides the contact area, allowing specific portions to accommodate coils while maintaining protective gaps in other areas, thus segmenting the thermal exposure zones.
2Reliability
If the connection coil is accommodated in the insulation plate, then the insulation plate provides electrical insulation, but heat application during joining damages the insulation plate
Solution Approach 1:
The groove structure serves as a thermal intermediary, allowing the connection coil to be accommodated within the insulation plate while maintaining a protective gap. This gap acts as a thermal barrier that preserves electrical insulation functionality while protecting against heat damage during joining operations.
Solution Approach 2:
The groove introduces a dimensional feature (depth) into the insulation plate structure. By creating a recessed accommodation space, the design separates the electrical insulation function (maintained by the insulation plate material) from the thermal exposure risk (mitigated by the gap created in the third dimension).
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 design effectively suppresses insulation damage and maintains insulation performance by creating gaps between the connection coils and the insulation plate, ensuring reliable electrical connections and improved thermal management.
Implementation Method 1
the abutment portion is exposed from an axial end face of the insulation plate as viewed from an axial direction... in a hole portion where the abutment portion is accommodated, the connection coil and the slot coil are spaced apart from the insulation plate in the circumferential direction
Implementation Method 2
the connection coil and the slot coil are joined together in such a state that a surface contact pressure is generated between the connection coil and the slot coil at the abutment portion
Data Source
AI summary
A stator for an electric rotary machine including a stator core and a coil, wherein: the coil has plural slot coils and plural connection coils, each slot coil being inserted into the slot, each connection coil connecting the slot coils in a position lying further axially outwards than an axial end face of the stator core, and the coil being constituted in such a way that the slot coil and the connection coil are joined at an abutment portion; and in a hole portion, where the abutment portion is accommodated, of a insulation plate, the connection coil and the slot coil are spaced apart from the insulation plate in the circumferential direction to thereby form a first gap portion.