Continuous Insulating Paper Insertion for Stator Slots
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Solution Overview
Problem
The existing method of inserting insulators and prewound coils into stator slots of electric machines is cumbersome, increases manufacturing costs, and risks accidental contact between coils and laminations, leading to potential damage.
Innovation Solution
A system and method for inserting continuous insulating paper and prewound coils with longitudinal legs into stator slots using a radially movable holder, which simultaneously inserts the paper and coils, ensuring complete coverage and preventing contact between the coil and laminations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional slot liners are manually or automatically inserted into slots, then insulating paper can be placed in slots, but the process becomes cumbersome and manufacturing costs increase
Solution Approach 1:
The patent combines the slot liner and the coil insertion operation into a single integrated process. The slot liner is pre-formed with U-shaped arms that extend beyond the slot, and the coil is inserted through these arms in one continuous motion, eliminating the need for separate liner insertion and coil placement steps. This merging of operations directly reduces manufacturing complexity while maintaining insulation coverage.
Solution Approach 2:
The slot liner is pre-formed with U-shaped arms that extend beyond the slot before insertion. This preliminary shaping of the liner allows it to automatically guide the coil during insertion and provide complete coverage of the teeth without requiring additional adjustment or folding operations after the coil is in place. The preliminary action eliminates subsequent manual manipulation steps.
2Reliability
If excess material of slot liners is removed or folded after coil insertion, then complete insulation can be achieved, but additional manufacturing steps are required
Solution Approach 1:
The slot liner is pre-formed with U-shaped arms of specific dimensions that extend beyond the slot. These arms are designed to automatically fold over the coil during or immediately after insertion, providing complete coverage of the teeth without requiring separate removal or folding operations. The preliminary configuration of the liner eliminates post-insertion manipulation steps.
Solution Approach 2:
The U-shaped arms of the slot liner automatically fold over the coil during the insertion process itself, without requiring external manipulation. The liner's own geometry enables it to self-adjust and provide complete coverage, eliminating the need for additional manufacturing steps to achieve proper insulation coverage.
3Ease of operation
If U-shaped slot liners with extended arms are used, then coil guidance is improved, but the liners become more complex to manipulate
Solution Approach 1:
The U-shaped arms of the slot liner are integrated with the coil insertion operation itself. The arms serve dual purposes: they guide the coil during insertion and automatically fold over to provide insulation coverage. By merging the guidance function with the insulation function in a single component, the overall system complexity is reduced despite the extended arm geometry.
Data Source
AI summary
The insertion of electrically insulating paper from a continuous roll into slots of a stator created by outwardly projecting teeth is described herein. The insertion of the insulating paper is done by the insertion of prewound coils in the stator slots. The electrically insulating paper is not cut prior to its insertion in the slots, thereby completely covering the outer surface of the stator. The insertion systems and methods described herein are also optionally concerned with the insertion of interphase insulation paper between the different coils inserted in the stator slots and with the insertion of slot closing wedges.