Stator Insulator Segmentation for Coil Assembly
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Solution Overview
Problem
Conventional stators of rotating electrical machines face productivity issues due to interference between coils and insulators during assembly, leading to inefficiencies in insulation and potential malfunctions.
Innovation Solution
A stator design featuring a sheet-like insulator bent to form cylindrical spaces around coils, with bent portions extending between them, allowing for stable and efficient insulation and easy insertion of coils, thereby enhancing productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional insulator is used to insulate conducting coils in slots, then insulation reliability is improved, but assembly complexity and interference between coils and insulator increase
Solution Approach 1:
The insulator is divided into multiple independent insulating pieces, each placed at specific locations within the slot (between adjacent coils and between coils and slot walls). This segmentation allows each piece to perform a specific insulation function independently, simplifying the overall assembly process while maintaining comprehensive insulation coverage.
Solution Approach 2:
The insulator is extracted from a single complex component design and separated into multiple simple insulating pieces. This extraction approach eliminates the interference problems associated with conventional single-piece insulators while maintaining the necessary insulation functions through distributed placement of simpler components.
2Reliability
If a conventional insulator design is used, then insulation function is achieved, but productivity is reduced due to interference during assembly
Solution Approach 1:
By segmenting the insulator into multiple small pieces placed at critical locations, the assembly process becomes simpler and faster. Each insulating piece can be independently positioned without causing interference with coils, thereby improving productivity while maintaining insulation reliability.
Solution Approach 2:
The insulating pieces are pre-positioned in the slots before coil assembly. This preliminary action ensures that insulation is already in place, preventing interference during subsequent coil installation and streamlining the overall assembly process for higher productivity.
3Reliability
If insulator is placed around each coil in conventional manner, then insulation between coils is improved, but manufacturing complexity increases
Solution Approach 1:
The insulation system is segmented into multiple simple insulating pieces rather than one complex component. Each piece can be manufactured independently using simple processes, and their distributed placement achieves comprehensive coil insulation without requiring complex manufacturing procedures.
Solution Approach 2:
Insulation is applied locally at specific critical locations within the slot (between adjacent coils and at coil-slot interfaces) rather than uniformly around each coil. This local quality approach maintains necessary insulation reliability while significantly simplifying manufacturing complexity.
Data Source
AI summary
A stator of a rotating electrical machine that can realize productivity growth, compared with a conventional technique is provided. A stator of a rotating electrical machine includes a slot; a plurality of coils disposed within the slot; and an insulator disposed around the coils within the slot. The insulator has an outer peripheral portion that surrounds the plurality of coils; and a bent portion that extends from the outer peripheral portion between the coils and that is folded back on a tip end.