Split Core Stator Resin Box Attachment Mechanism
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Solution Overview
Problem
Existing stators of rotary electrical machines face issues with insulation failures due to incomplete filling of insulating resin material in annular grooves, leading to increased manufacturing costs and potential operational inhibition.
Innovation Solution
A stator design featuring a core unit with annularly arranged split cores, a bus ring, and accommodating boxes with radially inward and outward engaged portions, allowing for easy attachment and ensuring complete filling of insulating resin material, preventing insulation failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating resin material is filled in the connected annular groove entirely along the circumferential direction, then the groove is filled with insulating material, but the amount of resin material used is large and manufacturing costs increase
Solution Approach 1:
The patent divides the continuous annular groove into multiple separate groove portions formed at different insulators. Each groove portion is filled independently with insulating resin material, replacing the need for a continuous annular groove that would require large amounts of resin material.
Solution Approach 2:
The patent applies insulating resin material locally at specific groove portions rather than filling the entire annular groove continuously. This localized application reduces the total quantity of resin material needed while maintaining insulation reliability at critical locations.
2Reliability
If the connected annular groove is filled with insulating resin material, then insulation is provided, but small portions of the groove are difficult to fill and insulation failure may occur
Solution Approach 1:
The patent segments the continuous annular groove into multiple discrete groove portions at different insulators. This segmentation makes it easier to ensure complete filling of each individual groove portion, as small gaps or incomplete filling in one location do not compromise the entire insulation system.
Solution Approach 2:
The groove portions are formed on the insulators before the coils are assembled into the final stator configuration. This preliminary formation allows for easier and more complete filling of the grooves with insulating resin material before the structure becomes complex and difficult to access.
3Ease of manufacture
If resin boxes are attached to insulators, then assembly is facilitated, but proper attachment requires precise positioning and alignment
Solution Approach 1:
The patent divides the stator into modular split cores with insulators that have groove portions formed directly on them. Resin boxes are attached to these individual insulator modules before final assembly, making the attachment process easier and more precise at the modular level rather than attempting to attach to the entire assembled stator.
Solution Approach 2:
The resin boxes are designed to fit within or attach to the modular insulator structures, creating a nested arrangement where smaller components (resin boxes) are attached to intermediate structures (insulators) that are themselves part of the larger stator assembly. This nesting facilitates easier attachment while maintaining precision.
Data Source
AI summary
A stator of a rotary electrical machine, includes a core unit configured by a plurality of core assemblies each including a laminated steel plate, an insulator, and a coil; a bus ring facing the core unit; and an accommodating box arranged at the insulator, accommodating an end portion of the coil, and including radially inward and outward engaged portions, the insulator including radially inward and outward extending portions, the radially inward extending portion including a radially inward engagement portion about which the accommodating box rotates in a radial direction of the core unit from an initial attachment position to an attached position and which engages with the radially inward engaged portion, the radially outward extending portion including a radially outward engagement portion which engages with the radially outward engaged portion in accordance with the rotation of the accommodating box to move the accommodating box in the radial direction.