Non-conductive Stator Retention Member for Conductor Interference
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Solution Overview
Problem
Existing electric machines face challenges in securely retaining conductors within stator slots, particularly in open slot geometries, which can lead to interference with the rotor and require complex staking processes or multiple parts for support.
Innovation Solution
A conductor retention member made from a non-electrically conductive material with radial edges and openings is designed to fit at the axial ends of the stator core, featuring compliant elements and locking mechanisms that allow easy conductor insertion and secure retention, reducing interference and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If open stator slots are used for conductor insertion, then ease of conductor loading is improved, but conductor retention reliability deteriorates due to potential interference with the rotor
Solution Approach 1:
A non-conductive retention member is introduced as an intermediary component between the conductor and the stator slot. This retention member has openings that register with the stator slots and provide a secure interface for holding conductors, preventing rotor interference while maintaining easy conductor loading through the open slot geometry
2Reliability
If staking process is used to support conductors in open slots, then conductor retention is improved, but manufacturing complexity worsens due to additional process steps
Solution Approach 1:
The retention member is designed with compliant elements that automatically deform and lock onto the conductors during assembly. The spring-like fingers engage with the conductors through the openings, providing self-retention without requiring external staking equipment or additional manufacturing steps
Solution Approach 2:
The retention member combines multiple functions into a single component: it provides mechanical retention through compliant elements, electrical isolation through non-conductive material, and structural support through the tooth-like projections. This eliminates the need for separate staking or wedging operations
3Reliability
If slot wedges are used to support conductors, then conductor retention is improved, but device complexity worsens due to additional parts
Solution Approach 1:
The retention member integrates the function of slot wedges into its tooth-like projections that extend into the stator slots. These projections provide the wedge effect for securing conductors while being part of a single unified component rather than separate wedge pieces
Solution Approach 2:
The retention member serves multiple purposes simultaneously: it acts as a conductor support, an electrical insulator, a mechanical retainer through compliant elements, and a structural element through its tooth projections. This multi-functionality eliminates the need for separate wedge components
Data Source
AI summary
A conductor retention member for a stator core includes a body formed from a non-electrically conductive material. The body includes a radial outwardly facing edge and a radial inwardly facing edge. A plurality of openings extends between the radial inwardly facing edge and the radial outwardly facing edge formed in the body. The body is configured and disposed to be arranged at an axial end of the stator core with the plurality of openings registering with corresponding ones of a plurality of stator slots.