Motor Stator Insulation Plate Design for Winding Space Optimization
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Solution Overview
Problem
Conventional motor stator winding insulation structures face inefficiencies in alignment and space reduction, leading to reduced motor performance and safety concerns due to overlapping insulation plates, which necessitate larger motor sizes and increased thickness for safety compliance.
Innovation Solution
An open-configuration, sheet-like insulation plate design that covers the edge surfaces of arrayed holes, allowing for easier alignment and increased insulation spacing, with end tabs extending outside the slot opening to maximize winding space and meet safety requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If overlapping insulation plates are used to meet safety spacing requirements, then insulation safety is improved, but the available winding space is reduced and motor size increases
Solution Approach 1:
The insulation plate transitions from a conventional flat configuration to a three-dimensional contoured structure that conforms to the curvature of the stator inner circumferential surface. This dimensional change allows the insulation plate to wrap around and cover the edge surfaces of arrayed holes more effectively, increasing insulation spacing without requiring increased motor dimensions.
Solution Approach 2:
The insulation plate features non-uniform thickness distribution with thicker regions positioned at critical locations where insulation spacing is most needed (near edge surfaces of arrayed holes) and thinner regions in areas where less insulation is required. This local quality variation optimizes insulation effectiveness while minimizing overall space consumption.
2Reliability
If insulation plates are fitted in an overlapping arrangement from opposite ends, then insulation coverage is achieved, but alignment efficiency is reduced
Solution Approach 1:
Instead of fitting insulation plates from opposite ends of the stator (conventional approach), the invention inverts the assembly sequence by inserting insulation plates through the end faces of the stator along with the phase winding in a single coordinated operation. This inversion of the assembly methodology eliminates the need for separate overlapping operations and improves alignment efficiency.
Solution Approach 2:
The insertion of insulation plates and phase winding are merged into a single assembly operation. The insulation plates and winding are inserted simultaneously through the same opening, combining two previously separate steps into one efficient process that improves productivity while ensuring proper alignment.
3Reliability
If thicker insulation plates are used to meet safety regulations, then insulation safety is improved, but the available winding space is reduced
Solution Approach 1:
The insulation plate employs non-uniform thickness distribution with localized thickening at critical areas (edge surfaces of arrayed holes) where insulation spacing requirements are most stringent, while maintaining thinner sections in areas where less insulation is needed. This allows meeting safety regulations without uniformly reducing winding space.
Solution Approach 2:
The insulation plate adopts a three-dimensional contoured design that conforms to the stator's curvature and wraps around edge surfaces, providing enhanced insulation coverage in critical dimensions without requiring uniform thickness increases that would consume excessive winding space.
Data Source
AI summary
The present invention provides an improved insulation structure for winding of motor stator, which is an improved design of structure for providing effective insulation for stator winding and improving winding volume. A stator piece that is arranged inside a motor body forms arrayed holes for wire winding. The holes receive insulation plates that are configured to correspond to the shape of the holes to be fit therein. Opposite ends of the stator piece receive end rings to fix and assemble thereto. End tabs formed at edges of the insulation plates are arranged to fit into and cover edge surface of a winding slot of each of the holes to realize complete coverage of the insulation for stator winding thereby ensuing operation safety when the motor is activated and put into operation.