Wound Stator Insulation System for Phase Isolation
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Solution Overview
Problem
Power steering motors face issues with short circuits between phases, which can prevent steering wheel movement, and current leakage between stator windings due to compromised insulation, leading to diminished motor performance.
Innovation Solution
A wound stator design with an insulation system using insert members and septum walls that provide complete phase-to-phase and turn-to-turn isolation, eliminating the need for additional insulation on the wire and minimizing the gap between stator teeth, thereby preventing short circuits and leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If known motor winding techniques are used, then the winding process can be completed, but current leakage between adjacent windings occurs due to compromised insulating coating
Solution Approach 1:
The patent applies preliminary action by pre-installing insulating structure in the stator slots before the winding operation. This insulating structure is positioned in advance to guide the wire and maintain proper spacing between adjacent windings, preventing insulation compromise during the winding process itself.
Solution Approach 2:
The patent uses an insulating structure as an intermediary element between adjacent windings. This structure acts as a mediator that maintains electrical isolation between phases and prevents current leakage, while also serving as a wire guide during the winding operation.
2Reliability
If relay is added to open short in windings, then safety is improved, but device complexity increases
Solution Approach 1:
The patent extracts the safety function from a separate relay component and integrates it into the insulating structure itself. The insulating structure is designed to automatically prevent short circuits between phases through its physical configuration and material properties, eliminating the need for an external relay while maintaining safety.
3Ease of manufacture
If insulating coating on wire is relied upon, then the winding process can proceed, but insulation may be compromised during winding
Solution Approach 1:
The patent applies preliminary action by pre-installing insulating structure in the stator slots before the winding operation. This insulating structure is positioned in advance to guide the wire and maintain proper spacing between adjacent windings, preventing insulation compromise during the winding process itself.
Solution Approach 2:
The patent provides beforehand cushioning by placing an insulating structure in the stator slots prior to winding. This structure serves as a protective barrier that cushions and protects the wire insulation from damage during the winding operation, ensuring insulation integrity is maintained.
Data Source
AI summary
A wound stator for a dynamo-electric machine comprising a stator stack having a unitary cylindrical yoke and a plurality of circumferentially spaced, radially inward extending stator teeth defining stator slots therebetween. A winding is formed by a strand of wire forming turns around each stator tooth, each winding including a first lead end extending from a stator slot on a first side of a respective stator tooth and a second lead end extending from a stator slot on a second side of the respective stator tooth. An insulation system is provided including an insulating structure septum extending through each stator slot between windings located on two adjacent stator teeth, the turns of each winding located between a respective stator tooth and a first surface of the insulating structure septum engaged with the winding.