Stator Interphase Insulation Sheet Retaining Mechanism
Solution Overview
Problem
Existing stator designs face challenges in ensuring reliable isolation between coil ends of different phases and efficient assembly processes, particularly in preventing displacement and interference during coil insertion and winding.
Innovation Solution
A stator design incorporating a stator core with teeth and slots, interphase insulation sheets with retaining pieces, and wedges with tapered projecting portions, which securely retain the insulation sheets and allow them to conform to coil ends, thereby ensuring effective isolation and reducing assembly time by omitting bonding and folding steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation paper is assembled by bonding nose portions to flat portions, then reliable isolation between coil ends is achieved, but assembly complexity and time increase due to bonding and folding steps
Solution Approach 1:
The patent extracts the bonding and folding operations from the assembly process by designing the interphase insulation sheet with pre-formed retaining pieces that snap into retaining grooves on the coil ends, eliminating the need for adhesive bonding and complex folding steps while maintaining reliable isolation
Solution Approach 2:
The interphase insulation sheet is segmented into multiple functional portions: sheet body portions for isolation, bridge portions for connection, and retaining pieces for mechanical attachment. This segmentation allows each component to perform its specific function independently, simplifying the overall assembly process
2Reliability
If traditional insulation paper with bonding is used, then coil ends are isolated, but productivity decreases due to multiple assembly steps
Solution Approach 1:
The retaining pieces are pre-formed on the interphase insulation sheet during manufacturing, and the coil ends are pre-prepared with retaining grooves. This preliminary preparation eliminates the need for bonding and folding operations during assembly, significantly improving productivity while ensuring reliable isolation
Solution Approach 2:
The interphase insulation sheet performs self-attachment through the snap-fit mechanism between retaining pieces and retaining grooves, eliminating the need for external bonding agents or complex assembly equipment, thereby increasing assembly speed and productivity
3Ease of manufacture
If insulation sheets are designed without retaining pieces, then manufacturing is simpler, but displacement and interference during coil insertion occur
Solution Approach 1:
The retaining pieces act as intermediary elements that mediate between the interphase insulation sheet and the coil ends, providing mechanical attachment without complicating the manufacturing of the sheet itself. The retaining grooves on the coil ends serve as the receiving structure for these intermediary retaining pieces
Data Source
AI summary
A stator includes a stator core, slots, coils, an interphase insulation sheet, and wedges. The interphase insulation sheet is provided between coil ends of adjacent coils having different phases among the coils. The interphase insulation sheet includes a first sheet body portion, a second sheet body portion, and a first bridge portion. The first and second sheet body portions respectively have first and second retaining pieces. The first retaining piece projects from the first sheet body portion toward the second sheet body portion in the developed state of the interphase insulation sheet. The second retaining piece projects from the second sheet body portion toward the first sheet body portion in the developed state of the interphase insulation sheet. The first and second retaining pieces are retained by projecting portions of the wedges.