Integrated Stator Slot Bobbin for High-Voltage Coil Insulation
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Solution Overview
Problem
The existing insulation methods between a stator core and coils in driving motors, particularly in open-end winding structures, are inadequate for high voltage applications, leading to partial discharge and reduced insulation performance due to the difficulty in processing insulating materials and the inability to effectively manage two-stage voltage distribution.
Innovation Solution
A bobbin structure with an integral body and partition, formed from plastic, is inserted into slots of a stator core to provide insulation between coils and the stator core, with partitions strategically placed between specific layers to manage voltage differences and prevent partial discharge, and extensions for secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating paper is inserted between stator core and coils to prevent partial discharge, then insulation performance is improved, but manufacturing complexity and processing difficulty increase
Solution Approach 1:
The patent combines the insulating paper and the bobbin structure into a single integrated component. The insulating paper is integrated into the bobbin structure, eliminating the need for separate insertion steps and reducing manufacturing complexity while maintaining the insulation function between stator core and coils
Solution Approach 2:
The insulating paper is pre-integrated into the bobbin structure during manufacturing, so that the insulation function is already prepared before the coil insertion process. This preliminary integration simplifies the assembly process and reduces processing difficulty during motor manufacturing
2Ease of manufacture
If traditional insulating structures are used in open-end winding structures, then manufacturing is simplified, but insulation performance deteriorates due to inability to reflect two-stage voltage distribution
Solution Approach 1:
The bobbin structure is segmented into multiple sections with different insulating properties. The structure includes a first insulating section for the first voltage stage and a second insulating section for the second voltage stage, allowing differential insulation treatment that reflects the two-stage voltage distribution in open-end winding structures
Solution Approach 2:
Different regions of the bobbin structure are assigned different insulating qualities and material properties. The local insulating characteristics are optimized according to the specific voltage stress conditions at different locations, providing enhanced insulation performance where needed while maintaining manufacturing feasibility
3Power
If high voltage is applied to driving motor to improve performance, then power output increases, but partial discharge occurs and insulation performance deteriorates
Solution Approach 1:
The bobbin structure incorporates pre-designed insulating barriers and protective structures that cushion against high voltage stress before partial discharge can occur. The integrated insulating paper and partition structures create protective zones that prevent discharge initiation, allowing high voltage operation without the harmful effects of partial discharge
Data Source
AI summary
A bobbin structure is inserted into a slot defined in a stator core. The bobbin structure includes a body configured to contact an inner wall of the slot and at least one partition provided inside the body to insulate at least some coils, inserted into the slot so as to be arranged in a plurality of layers, from each other. The body and the at least one partition are formed integrally with each other.