Stator Insulator Protrusions for Coil Winding Stability

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Solution Overview

Problem

The existing methods for producing stators for rotary electric machines require dedicated retaining tools for each machine type, leading to increased labor and production costs due to variations in split core shapes and curvatures, which complicates the winding process and affects the regularity of the coil.

Innovation Solution

A stator design featuring split iron cores combined in an annular shape with insulators having protrusions that deform during winding, allowing for secure fixation without the need for dedicated retaining tools, and a producing method that uses holding claws to retain the insulators with the split iron cores, enabling efficient coil winding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If dedicated retaining tools are used for each machine type, then the positional relationship between insulators and split core is stabilized, but production cost and labor increase due to tool replacement requirements

Engineering Contradiction:

Improvepositional relationship stabilityVSAvoidproduction cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The insulator is designed with self-retaining protrusions that automatically engage with grooves on the split core during assembly. This self-service mechanism eliminates the need for external retaining tools, allowing the insulator to secure itself to the split core without additional equipment or tool replacement, thereby reducing production cost while maintaining positional stability

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The retaining function is merged into the insulator structure itself through integrated protrusions. Instead of using separate retaining tools, the insulator combines both insulation and retention functions in a single component, eliminating the need for dedicated retaining tools for each machine type and reducing labor associated with tool replacement

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If insulators are assembled separately and then integrated with split core, then insulation is ensured, but displacement occurs during winding due to tension, deteriorating coil regularity

Engineering Contradiction:

Improveinsulation effectivenessVSAvoidcoil regularity

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The insulator is pre-assembled with the split core using the self-retaining protrusion mechanism before the winding process begins. This preliminary action ensures that the insulator and split core are securely connected in advance, preventing displacement during winding and maintaining coil regularity while ensuring insulation effectiveness

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If multiple retaining tools are used for different machine types, then various split core shapes can be accommodated, but device complexity and labor for tool replacement increase

Engineering Contradiction:

Improvecompatibility with split core variationsVSAvoidnumber of retaining tools

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The insulator with self-retaining protrusions is designed as a universal component that can accommodate various split core shapes and curvatures. The protrusions adapt to different geometries without requiring dedicated retaining tools for each machine type, thereby reducing device complexity and eliminating labor associated with tool replacement while maintaining versatility

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution reduces production costs by eliminating the need for multiple retaining tools and improves coil regularity and output by stabilizing the positional relationship between the split core and insulators during winding.

Implementation Method 1

the insulators have protrusions protruding from end surfaces in a circumferential direction of each yoke portion, and when the coil is wound around the tooth portion, each protrusion is deformed, thereby being fixed together with the yoke portion

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS11437873B2Stator with split iron cores and insulators with protrusions

Publication Date: 2022.09.06 MITSUBISHI ELECTRIC CORP

AI summary

A plurality of split iron cores combined with each other to form an annular shape and having yoke portions arranged along an outer circumference of the annular shape and tooth portions protruding to an inner side in a radial direction from the yoke portions, insulators disposed at both ends in an axial direction of each split iron core, and a coil wound around each tooth portion through at least parts of the insulators, are included. The insulators have protrusions protruding from end surfaces in a circumferential direction of each yoke portion. When the coil is wound around the tooth portion, each protrusion is deformed, thereby being fixed together with the yoke portion.