Stator Insulation Creepage Distance via Segmented Elements
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Solution Overview
Problem
The existing stator assembly in brushless motors does not effectively increase the creepage distance between the stator winding and the stator core, which is crucial for improving insulation safety.
Innovation Solution
The stator assembly includes a stator core with inwardly extending teeth, two insulating frames, and insulating elements that extend between these frames to increase the creepage distance, with specific tab and protrusion designs to enhance insulation and facilitate assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional insulating frames and insulating papers are used to insulate the stator winding from the stator core, then the insulation structure is simple, but the creepage distance between the stator winding and the stator core is insufficient
Solution Approach 1:
The insulating element is divided into multiple functional sections: a body portion fitted within the winding passage, first side portions extending along the inner surface of the winding passage, and second side portions extending across the winding opening. This segmentation allows each part to perform specific insulation functions, thereby increasing the overall creepage distance while maintaining structural organization
Solution Approach 2:
The insulating element extends in multiple spatial dimensions: axially between the first and second insulating frames, radially along the inner surface of the winding passage, and circumferentially across the winding opening. This multi-dimensional extension significantly increases the creepage distance compared to traditional single-layer insulating papers
2Reliability
If insulating elements extend between insulating frames to increase creepage distance, then insulation safety is improved, but the manufacturing complexity increases
Solution Approach 1:
Multiple insulating functions are merged into a single integrated insulating element: the body portion provides base insulation, the first side portions extend along the winding passage inner surface to increase axial creepage distance, and the second side portions extend across the winding opening to provide additional insulation layers. This consolidation simplifies the assembly process compared to installing multiple separate insulating components
Solution Approach 2:
The insulating element acts as an intermediary component between the stator winding and the stator core, providing a multi-layered insulation barrier that increases creepage distance while facilitating assembly through its integrated design that combines multiple insulation functions in one piece
Data Source
AI summary
An electric motor includes a stator and a rotor. The stator includes a stator core, a stator winding, a first insulating frame, a number of first insulating elements, and a number of second insulating elements. The stator core includes a number of teeth. Adjacent teeth form a winding passage defining a winding opening. Each first insulating element is assembled within the corresponding winding passage. Two end portions of each second insulating element are placed over the corresponding winding opening.