Stator Laminate Ridge for Precise Varnish Slot Filling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The application of varnish to electric motors can result in excess varnish flowing away from intended locations, leading to increased varnish usage and potential disruptions in the manufacturing process.
Innovation Solution
A stator design for electric motors that includes an outer laminate with a ridge configured to direct varnish into specific slots, and a method where varnish is deposited onto the outer laminate, accumulated by the ridge, and then directed into the slots using the ridge's sloped side.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If varnish is applied to the stator without flow control features, then the stator receives varnish coverage, but excess varnish flows away from intended locations increasing total varnish usage
Solution Approach 1:
The ridge structure acts as an intermediary element between the varnish application point and the slot. It intercepts the flowing varnish, redirects it along its sloped surface, and channels it precisely into the slot opening, preventing stray flow and reducing overall varnish consumption.
Solution Approach 2:
The ridge introduces a localized geometric feature with specific properties (sloped surface, defined edge) at the critical location where varnish flow needs control. This local modification creates a flow guidance function without altering the entire stator structure.
2Reliability
If varnish flows freely over the stator surface, then complete coverage is achieved, but varnish disrupts manufacturing by interfering with other parts
Solution Approach 1:
The ridge structure extracts and contains the varnish flow within a defined path. By creating a physical barrier and guidance feature, it prevents varnish from spreading to areas where it would cause manufacturing disruptions, while still ensuring adequate coverage of the slot area.
3Manufacturing precision
If a ridge structure is added to control varnish flow, then varnish placement precision improves, but device complexity increases
Solution Approach 1:
The ridge is implemented as a simple, segmented geometric feature that can be integrated into the existing stator lamination structure. It divides the varnish flow path into controlled segments, guiding the liquid through a defined trajectory without requiring complex mechanical systems.
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 effectively reduces the amount of varnish used by controlling its flow into specific slots, thereby improving the manufacturing efficiency of electric motors and preventing varnish from interfering with other parts of the stator.
Implementation Method 1
the ridge includes a sloped side angled toward the first slot to have the varnish flow down the sloped side to the first slot
Implementation Method 2
the ridge is configured to direct varnish applied by a varnish injector into the first slot and the second slot
Data Source
AI summary
A method for applying varnish to a stator of an electric motor includes depositing varnish onto an outer laminate of the stator, accumulating the deposited varnish with a ridge on the outer laminate, and directing the accumulated varnish into a slot of the outer laminate with the ridge.