Stator Insulator Design for Coil Insertion
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Solution Overview
Problem
In rotating electric machine stators, the insertability of coils is poor due to interference between deformed coils and stepped insulators, which compromises the space factor and insulating performance, especially when fitting the last coil in narrow slots.
Innovation Solution
The design features insulators with first and second surfaces, where the second surfaces connect the first surfaces and are parallel to the outer peripheral surfaces of the coil, preventing interference and ensuring insulating performance by allowing the coil to be inserted without deforming the inner peripheral surfaces, thus improving coil insertability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stepped insulators are used to improve space factor, then insulating performance is improved, but coil insertability deteriorates due to interference between deformed coils and insulator steps
Solution Approach 1:
The insulator is designed with different surface characteristics: first surfaces (stepped portions) that provide insulation and spacing, and second surfaces (smooth connecting portions) that enable coil insertion. This local differentiation allows the insulator to simultaneously provide insulating performance and facilitate coil insertability without interference.
2Ease of operation
If coil width is reduced to improve insertability, then ease of operation improves, but space factor decreases causing performance deterioration
Solution Approach 1:
The insulator acts as an intermediary element between the tooth and the coil. By providing smooth second surfaces that guide the coil during insertion, the insulator enables easier coil installation without requiring the coil itself to be narrower, thereby maintaining the space factor while improving insertability.
Data Source
AI summary
A stator of a rotating electric machine includes a stator core, a plurality of insulators and a plurality of concentrated winding coils. The stator core includes an annular yoke and a plurality of teeth. The insulators are located along outer peripheral wall surfaces of the teeth. Each of the insulators includes a plurality of first surfaces and a plurality of second surfaces. The second surfaces connect the first surfaces. The coils are fitted on the teeth on which the insulators have been placed from a radially inner side thereof. The first surfaces of each of the insulators are in contact with inner peripheral surfaces of the coil that is placed on the outer periphery of the insulator.