Stator Slot Varnish Application for Controlled Flow Coverage
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Solution Overview
Problem
Varnish application in electric motors often results in unintended flow, leading to increased usage and disruption of other motor components, necessitating improved application methods to control varnish distribution.
Innovation Solution
A method involving flexible and straight nozzles positioned at the outer and inner diameters of stator slots, applying varnish at specific angles and distances, ensuring complete coverage of wire slots during stator rotation, with both nozzles working in tandem to control varnish flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If varnish is applied to electric motors using traditional methods, then the stator components are protected against corrosion and contaminants, but the varnish flows away from the intended location, increasing total varnish usage and potentially disrupting operation of other motor parts
Solution Approach 1:
The patent divides the varnish application process into two separate injection points: one at the outer diameter of the stator and another at the inner diameter. This segmentation allows precise control of varnish flow into specific wire slots, preventing unwanted flow to other areas while ensuring complete coverage of the intended components.
Solution Approach 2:
The patent applies varnish locally to specific wire slots through targeted injection points positioned between adjacent slots. By injecting at both outer and inner diameters, the system delivers varnish precisely where needed on the stator components, avoiding unnecessary application to other motor parts and reducing overall varnish consumption.
2Reliability
If varnish is applied to ensure complete coverage of wire slots, then protection is improved, but varnish may flow away from intended location and disrupt operation of other parts
Solution Approach 1:
By segmenting the application system into two separate injectors positioned at different diameters, the patent achieves complete coverage of wire slots while containing the varnish flow. The dual injection points work together to fill slots thoroughly without allowing excess varnish to escape to adjacent areas or other motor components.
Solution Approach 2:
The patent uses the stator structure itself as an intermediary to control varnish distribution. The dual injection system leverages the stator's geometry to guide varnish flow into the wire slots, using the motor component structure to contain and direct the protective coating away from sensitive areas.
Data Source
AI summary
A method to apply varnish to a stator of an e-motor includes injecting varnish at an outer diameter of a plurality of wire slots of the stator with flexible nozzle that is disposed between adjacent wire slots. The method further includes injecting varnish at an inner diameter of the wire slots.