Stator Insulating Paper Fixation for Slot Insertion and Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electric motors face difficulties in inserting and fixing phase-to-phase insulating paper due to thickness issues, leading to potential misalignment and increased manufacturing costs, especially when dealing with varying coil shapes and winding arrangements.
Innovation Solution
A stator configuration that includes a stator core with slots, coils, coil-to-coil insulating papers with protruding portions, and wedge insulating papers, where the coil end insulating papers have adhesive portions to securely adhere to the protruding portions, ensuring proper positioning and fixation of insulating papers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the phase-to-phase insulating paper is made thicker to prevent slipping, then it is easier to prevent misalignment, but it becomes difficult to insert into the slot
Solution Approach 1:
The insulating paper is divided into multiple segments: coil end insulating papers positioned at the ends and coil-to-coil insulating papers positioned in the slots. This segmentation allows each part to have optimized dimensions - the coil-to-coil insulating papers can be thin enough to easily insert into slots while the combined system provides sufficient thickness for preventing misalignment through the adhesive fixation system.
Solution Approach 2:
An adhesive tape is introduced as an intermediary element to fix the coil end insulating paper to the coil end. This adhesive mediator provides the necessary holding force to prevent slipping and misalignment without requiring the insulating paper itself to be thick, thus resolving the contradiction between prevention of misalignment and ease of insertion.
2Ease of manufacture
If the phase-to-phase insulating paper is made thinner to ease insertion, then it is easier to insert into the slot, but it becomes difficult to prevent slipping
Solution Approach 1:
The adhesive tape serves as a mediator that compensates for the reduced thickness of the insulating paper. By providing strong adhesive bonding between the insulating paper and the coil end, it ensures the insulating paper remains securely positioned without requiring increased thickness, thus maintaining both ease of insertion and prevention of misalignment.
Solution Approach 2:
The system merges multiple components (coil end insulating paper, coil-to-coil insulating paper, and adhesive tape) into a unified fixation system. This combination allows the thin insulating paper to be securely held in place through the adhesive, achieving both easy insertion and reliable misalignment prevention through the integrated system rather than relying on paper thickness alone.
3Manufacturing precision
If a special shaped insulating paper is used to match coil and slot geometry, then positioning accuracy is improved, but manufacturing cost increases and adaptability decreases
Solution Approach 1:
The coil end insulating paper and coil-to-coil insulating paper are designed as universal components that can be applied to various coil shapes, winding arrangements, pole numbers, and slot configurations. The adhesive fixation system provides the necessary positioning accuracy for different geometries without requiring custom-shaped insulating papers, thus achieving both positioning accuracy and adaptability through a standardized design.
Solution Approach 2:
The adhesive tape acts as a universal intermediary that can accommodate different coil and slot geometries. Rather than shaping the insulating paper to match specific geometries, the adhesive mediator adapts to various shapes and configurations, providing consistent positioning accuracy across different motor designs while maintaining versatility and reducing manufacturing costs.
4Reliability
If the insulating paper protrudes from the stator core to ensure coverage, then insulation reliability is improved, but the coil length becomes longer
Solution Approach 1:
The insulating paper system is segmented into coil end insulating papers positioned at the axial ends and coil-to-coil insulating papers positioned in the slots. This segmentation allows the insulating function to be distributed - the coil-to-coil insulating papers provide insulation within the slot area while the coil end insulating papers provide insulation at the ends, reducing the need for excessive protrusion and minimizing the impact on coil length while maintaining insulation reliability.
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 configuration allows for easy and secure positioning of coil-to-coil insulating papers, effectively preventing misalignment and reducing manufacturing costs, while being adaptable to various pole numbers and slot arrangements.
Implementation Method 1
each of the coil end insulating papers has an adhesive portion, and a plurality of the protruding portions are adhered to one coil end insulating paper
Data Source
AI summary
Provided are a stator having insulating paper positioned and fixed using an inexpensive and simple structure, a motor having the stator, and a method for manufacturing the stator. The stator 18 of a motor is provided with a stator core 26 having a plurality of slots 16, a plurality of coils 32 positioned in the slots, pieces of coil end insulating paper 40 that are positioned between a plurality of coil ends 44 and that insulate the coil ends 44 from each other, and a plurality of pieces of intercoil insulating paper 34 positioned in the slots 16, each of the plurality of pieces of intercoil insulating paper 34 having a projection 38 projecting from an axial end part 36 of the stator core. Each of the pieces of coil end insulating paper 40 has an adhesive part 42, and a plurality of projections 38 are affixed into a single piece of coil end insulating paper 40.