Stator Core Slot Liner Pre-Securing for High Fill Windings
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Solution Overview
Problem
High slot fill stators face challenges in inserting wires without damaging the thin slot liners, which can lead to electrical grounding and defective assemblies due to the lack of column strength and potential for the slot liners to be caught by the conductors during insertion.
Innovation Solution
The stator assembly secures the slot liner to the sides of the core slots using adhesives, tooling, or laminating with a spring material to prevent damage during the winding insertion process, ensuring proper electrical isolation between the windings and the core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thin slot liners are used to increase slot fill number, then productivity is improved, but reliability deteriorates due to lack of column strength and susceptibility to damage during insertion
Solution Approach 1:
The slot liner is pre-secured to the core slot using adhesives, tooling, or laminating with spring material before the winding insertion process begins. This preliminary action ensures the slot liner is properly positioned and supported before conductors are inserted, preventing damage during the insertion process while maintaining thin thickness for high slot fill numbers
Solution Approach 2:
An intermediary support structure (adhesive, tooling, or spring material laminate) is introduced between the thin slot liner and the insertion process. This intermediary provides the necessary column strength and support during insertion, allowing thin slot liners to be used without compromising reliability
2Productivity
If rectangular conductors with width closely fitting the slot width are used, then productivity is improved, but reliability deteriorates due to potential catching of slot liner edges during insertion
Solution Approach 1:
The slot liner is pre-secured to the core slot using adhesives, tooling, or laminating with spring material before the winding insertion process begins. This preliminary action prevents the slot liner edges from being caught by the rectangular conductors during insertion, maintaining electrical isolation integrity while allowing close-fitting conductors for high slot fill efficiency
Solution Approach 2:
The slot liner is provided with beforehand support through adhesives, tooling, or spring material laminating that acts as a cushion during the insertion process. This cushioning prevents direct contact and potential damage between the conductor edges and slot liner, ensuring reliability while maintaining high slot fill
Data Source
AI summary
A stator of a rotary electric machine having secured core slot insulators includes a multi-phase stator winding, having a plurality of slot segments that are adapted to be radially inserted into a plurality of circumferentially spaced axially-extending core slots in a surface of a cylindrically-shaped stator core. The stator winding includes the plurality of slot segments alternately connected at the first and second ends of the stator core by a plurality of end loop segments to form the winding. The plurality of core slots house an insulator to electrically isolate the slot segments from the core slots. The insulator is secured to the sides of the core slot prior to the process of radial inserting the plurality of slot segments into the plurality of core slots of the cylindrically-shaped stator core.