Segmented Stator Winding Insulation for Easier Pole Shoe Insertion
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Solution Overview
Problem
Conventional insulation devices for stator windings in electrical machines are difficult to install and often fail to provide complete electrical insulation between the stator winding and the pole shoe, leading to uncovered areas that compromise the insulation.
Innovation Solution
The insulation device is designed in two parts, with a plate-like base and a separate insulation element, featuring a through-opening and a base collar with interruptions that allow deformation for easier insertion and complete coverage of the pole shoe, ensuring electrical insulation between the stator winding and the pole piece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional housing-like electrical insulation device is used, then electrical insulation between pole shoe and stator winding is provided, but the device is relatively difficult to install and certain areas remain uncovered
Solution Approach 1:
The base collar is divided into multiple sections by introducing interruptions (gaps) in its structure. This segmentation allows each section to be flexibly deformed and inserted into the winding opening independently, significantly easing installation while maintaining complete insulation coverage when the sections are positioned around the pole shoe
Solution Approach 2:
The base collar is designed as a flexible structure that can be deformed during insertion and then returns to its original shape to provide complete coverage. This flexibility enables the insulation device to be easily installed while ensuring all areas between the pole shoe and stator winding are covered
2Reliability
If the base collar is made rigid to ensure complete coverage, then insulation reliability is improved, but insertion into the winding opening becomes more difficult
Solution Approach 1:
The base collar transitions from a static rigid structure to a dynamic flexible structure that can change its shape during insertion. The interruptions enable the collar to be compressed and deformed for insertion, then expand to provide complete coverage, resolving the contradiction between rigidity for coverage and flexibility for insertion
3Ease of manufacture
If the insulation device is designed as a single integrated piece, then manufacturing is simplified, but complete coverage of all areas is compromised
Solution Approach 1:
The base collar is segmented into multiple sections through interruptions, allowing each section to independently conform to the winding opening and pole shoe geometry. This segmentation ensures complete coverage of all areas while maintaining structural simplicity and ease of manufacture
Solution Approach 2:
The segmented base collar sections are designed to nest together around the pole shoe, with each section fitting into position to provide continuous insulation coverage. This nested arrangement ensures complete coverage while keeping the overall device structure simple and manufacturable
Data Source
Figure 1~3
Figure 4~6
AI summary
The invention relates to an insulation device (1) for electrically insulating a stator winding (21) of a stator (20) of an electrical machine with respect to a pole piece (22) of this stator (20). The insulation device (1) comprises a plate-like base (2), made of an electrically insulating material, preferably of an electrically insulating plastic, in which a substantially rectangular through-opening (3) is arranged, having two opposite narrow sides (4a, 4b) and two likewise opposite broad sides (5a, 5b). The through hole (3) is used to receive a pole piece of the stator (20). The insulation device comprises a base collar (10) integrally formed on the base, which extends along the two broad and narrow sides (4a, 4b, 5a, 5b) of the through opening (3) and encloses the through opening (3) in sections. The base (2) and the base collar (10) are thus formed in one piece and of the same material. The base collar (10) has in the region of the two narrow sides (4a, 4b) in each case an undercut (7a, 7b) forming a collar opening (6a, 6b). Furthermore, the insulation device comprises a (first) insulation element (7a), which is preferably plate-like in shape and is also separate from the base, for closing one (first) (6a) of the two collar openings (6a, 6b).