Electric Machine Stator Slot Support for Oil Cooling and Wire Protection
Solution Overview
Problem
The existing stator designs for electric machines require special lamellas for support points, which can damage conductor bundles during assembly and increase manufacturing costs, and also require separate slot insulation and complex cooling channel designs.
Innovation Solution
The support points are formed by twisting individual or groups of laminations of the laminated core, eliminating the need for special lamellas, and incorporating electrically non-conductive protective layers to prevent damage and simplify insulation, while maintaining efficient cooling by ensuring continuous flow through the slot gap channel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If special lamellas with clamping contours are used to form support points, then the conductor bundles can be clamped in the stator slots, but the conductor bundles are damaged during insertion and manufacturing costs increase
Solution Approach 1:
The harmful clamping contours are removed from the laminations. Instead of having protruding clamping structures that damage conductors, the support points are formed by twisting adjacent laminations to create interlocking structures that hold conductors without direct clamping pressure on them.
Solution Approach 2:
Instead of using protruding clamping contours that extend into the slot space and damage conductors, the invention uses recesses formed by twisting laminations. The support points are created by the interlocking of twisted lamination edges rather than by direct clamping force from protruding features.
2Reliability
If special lamellas are used to form support points, then the conductor bundles can be supported in the stator slots, but the device complexity and manufacturing costs increase
Solution Approach 1:
The laminations are designed with dual functionality: they provide both the magnetic core structure and the support points for conductors. By twisting adjacent laminations, the same lamination material serves both structural and support functions, eliminating the need for separate special lamellas.
Solution Approach 2:
The support function is merged into the regular lamination structure. Instead of having separate special lamellas with clamping contours, the support points are created by modifying the arrangement and orientation of standard laminations through twisting, combining the support function with the existing lamination stack.
3Stability of the object's composition
If clamping forces are applied to insert conductor bundles into stator slots, then the conductor bundles are secured in place, but the electrical insulation of conductor bundles is damaged
Solution Approach 1:
The twisted lamination edges act as intermediaries that provide mechanical support without direct clamping contact with the conductor bundles. The support points are formed by the interlocking geometry of twisted laminations, which hold conductors in place through geometric constraint rather than compressive force.
4Object-affected harmful factors
If separate slot insulation is used to protect conductors, then the conductors are protected from mechanical damage, but the manufacturing time and complexity increase
Solution Approach 1:
The twisted lamination structure provides built-in protection for conductors before they are subjected to mechanical stresses. The interlocking geometry of the twisted laminations creates a protective framework that cushions and protects conductors during insertion and operation, eliminating the need for additional insulation layers.
Data Source
AI summary
The invention relates to a stator (1) of an electric machine (23) having a stator axis (2) and having a laminated core (3) on which stator teeth (4) and stator slots (5) located between the stator teeth (4) are formed and which has a large number of laminations (6), wherein the stator teeth (4) are interconnected via an annular stator yoke (7), wherein a single conductor (9) or a conductor bundle (10) comprising a plurality of conductors (9), in particular a stack of flat-wire conductors, is provided in each of the stator slots (5) in order to form an electrical stator winding (8), wherein a plurality of support points (11) which are spaced apart from one another in the axial direction with respect to the stator axis (2) are formed in each of the stator slots (5) in order to clamp the conductor (9) or conductor bundle (10) in each stator slot (5), wherein at least one slot gap (19) is formed between the walls (4.2, 5.1) of each stator slot (5) and the conductor or conductor bundle (9, 10) arranged in the stator slot (5), which slot gap forms a slot gap channel (20) which extends in the axial direction and through which a cooling medium, in particular oil, can flow,characterized in thatthe support points (11) are each formed by twisting individual or a plurality of laminations (6) of the laminated core (3), in particular a group (12) or a plurality of groups (12) of laminations (6).