Stator Phase Insulation via Molded Coil Ends
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Solution Overview
Problem
Existing methods for insulating coil ends in electric machine stators are labor-intensive, time-consuming, and prone to quality issues due to manual placement of insulating papers, which hinders fully automatic production.
Innovation Solution
A stator design featuring a molded plastic body with concentric ring areas and channel-shaped receiving devices for secure and space-efficient insulation of coil ends, allowing for automatic coil placement and integration of insulation within the stator slots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual placement of insulating papers is used between coils, then insulation of coil ends can be achieved, but the process becomes labor-intensive and time-consuming
Solution Approach 1:
The patent applies preliminary action by pre-attaching insulating papers to the coil ends during coil manufacturing, before the coils are installed in the stator. This preliminary insulation preparation eliminates the need for manual placement during assembly, thereby improving production efficiency while maintaining insulation reliability. The insulating papers are fixed to the coil ends in advance, so they remain in position automatically when coils are mounted.
Solution Approach 2:
The patent merges the insulation function with the coil structure itself by integrating the insulating papers directly onto the coil ends. This combination creates a unified component where insulation and coil assembly are treated as one integrated unit, eliminating separate insulation placement operations and enabling fully automatic production while ensuring reliable insulation.
2Reliability
If manual placement of insulating papers is used, then insulation can be provided, but quality problems occur due to possible slipping of insulation papers
Solution Approach 1:
By performing insulation attachment in advance during coil manufacturing, the insulating papers are securely fixed to the coil ends before installation. This preliminary action ensures that the insulating papers cannot slip or displace during subsequent handling and assembly operations, thereby maintaining both insulation stability and positioning accuracy throughout the production process.
Solution Approach 2:
The patent applies self-service by designing the coil ends with integrated insulation features that automatically maintain their position during assembly. The insulating papers are attached in such a way that they self-align and self-secure when the coils are installed in the stator, eliminating the need for additional positioning operations and preventing slipping without requiring manual intervention.
3Reliability
If manual insulation placement is used, then coil end insulation can be achieved, but fully automatic production is not permitted
Solution Approach 1:
The patent enables full automation by performing insulation attachment as a preliminary operation during coil manufacturing. This advance preparation transforms the insulation process into an integrated part of coil production, which can be automatically performed using coil-winding machines with built-in insulation application capabilities. The result is that completely automatic production becomes feasible while maintaining high insulation quality standards.
Solution Approach 2:
By merging the insulation application process with the coil manufacturing process, the patent creates a unified automated production flow. The insulation papers are applied during the same automated coil-winding operation that creates the coils themselves, eliminating the need for separate manual insulation placement steps and enabling fully automatic stator assembly production while ensuring consistent insulation quality.
Data Source
AI summary
A stator for an electric machine includes a cylindrical stator body having several stator slots. A first coil is inserted into the stator slots for a first phase, where the first coil has a first coil end on at least one face of the stator body. A second coil is inserted into the stator slots for a second phase, where the second coil has a second coil end on the at least one face of the stator body. A third coil may be inserted into the stator slots for a third phase, where the third coil has a third coil end on the at least one face of the stator body. The stator includes a molded body for receiving and electrically insulating the coil ends, where the molded body extends in a first ring area and a second ring area concentric with respect to the first ring area.