Stator Phase Separator Mesh for Resin-Permeable Insulation
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Solution Overview
Problem
The existing production methods for rotary electrical machines face challenges with the use of surface insulating materials as phase separators, which are difficult to automate, prone to errors, and impede the flow of impregnation resin, leading to incomplete curing and potential machine failure under mechanical or thermal loads.
Innovation Solution
The implementation of insulating layers formed as a mesh-like structure with junctions and brace-like connections, made from plastic that can be sprayed onto the partial winding overhangs, allowing for easy resin flow during impregnation and automated application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flat paper or thin PET film is used as phase separator, then insulation between phases is achieved, but the impregnation resin flow is impeded leading to incomplete curing
Solution Approach 1:
The patent applies a porous plastic foam material as the phase separator instead of solid flat paper or thin PET film. The porous structure allows the impregnation resin to flow through the phase separator freely, ensuring complete curing while maintaining the insulating function between phases. The foam material's cellular structure provides both electrical insulation and permeability to the resin.
Solution Approach 2:
The patent uses a composite approach by combining the insulating properties of plastic foam with the permeability required for resin flow. The plastic foam material integrates both functions: electrical insulation between phases and allowance of resin penetration, resolving the contradiction between maintaining insulation and enabling complete curing.
2Reliability
If manual insertion of phase separators is used, then insulation is achieved, but production cannot be fully automated and errors occur
Solution Approach 1:
The patent replaces the manual mechanical insertion of phase separators with an automated spraying system that applies plastic foam material. The spraying apparatus can be integrated into the automated production line, eliminating manual operations and associated errors while maintaining reliable insulation between phases.
Solution Approach 2:
The patent changes the form and application method of the insulating material from solid sheets requiring manual insertion to sprayable plastic foam material. This parameter change enables automated application through spraying equipment, improving both automation extent and production reliability.
3Reliability
If surface insulating materials are used as phase separators, then insulation is achieved, but resin flow is blocked and quality issues arise
Solution Approach 1:
The patent employs porous plastic foam material that allows resin to flow through freely, preventing the quality issues associated with blocked resin flow. The porous structure maintains insulation while ensuring complete impregnation and curing, thereby improving manufacturing precision and quality.
Solution Approach 2:
The plastic foam material serves as a temporary structure during manufacturing that is later removed or decomposes, having served its insulating purpose during assembly and impregnation. This approach ensures quality curing without the need for permanent solid insulating barriers that would block resin flow.
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 approach enables fully automated and error-free application of insulating layers, ensuring seamless resin flow and complete curing, thereby enhancing the reliability and quality of the electrical machine.
Implementation Method 1
a respective insulating layer of plastic is sprayed at least onto the partial winding overhangs of the windings of the one phase
Data Source
AI summary
A stator of a rotary electrical machine includes a laminated core having grooves, windings inserted into the grooves for forming a multi-phase winding system, and an insulating layer made of plastic and sprayed between partial winding overhangs of the windings of phases inserted immediately one after the other. The insulating layer is formed as a mesh-like structure having junctions and brace-like connections running between the junctions.