Stator with Step Part Insulation for Compact Coil Arrangement
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Solution Overview
Problem
The existing stator design with swollen non-adhesion parts at the coil ends makes it difficult to closely arrange segment coils, leading to increased size and reduced electrical insulation reliability due to potential discharges between conductor parts and insulation films.
Innovation Solution
A stator design with a step part on the covered conductor part adjacent to the exposed conductor part, where the exposed conductor part has a thinner thickness than the covered conductor part, and both are covered with an electrical insulation film, forming a predetermined insulation gap to prevent discharges and allow closer coil arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the non-adhesion part has a swollen shape to reduce stress change, then the electrical insulation reliability is improved, but the overall size of the stator increases and the coil end parts cannot be closely arranged
Solution Approach 1:
The coil end part is segmented into three distinct regions: a covered conductor part with full insulation, a non-adhesion part with reduced adhesive force, and an exposed conductor part with no insulation film. This segmentation allows each region to serve its specific function while enabling closer arrangement of coil end parts.
Solution Approach 2:
Different portions of the coil end part have different insulation characteristics: the covered conductor part has complete insulation film coverage, the non-adhesion part has partial adhesive reduction, and the exposed conductor part has no insulation film. This local differentiation optimizes both electrical insulation and stress management.
2Volume of moving object
If the non-adhesion part has a flat shape to reduce stator size, then the overall size is reduced, but electric discharge occurs between the exposed conductor part and the insulation film of adjacent segment coils
Solution Approach 1:
The non-adhesion part acts as an intermediary zone between the covered conductor part and the exposed conductor part. By reducing the adhesive force in this intermediate region, the insulation film can deform more freely to maintain insulation gaps, preventing electric discharge while allowing compact arrangement.
3Reliability
If the thickness of the electrical insulation film is increased to prevent discharge, then the electrical insulation reliability is improved, but the overall size of the stator increases and the conductor part in the slot is reduced
Solution Approach 1:
The adhesive force parameter is changed in the non-adhesion part to be lower than in the covered conductor part. This parameter change allows the insulation film to have different deformation characteristics in different regions, enabling thin film design that prevents discharge without increasing overall size.
Data Source
AI summary
A stator has a stator core composed of teeth and slots. Segment coils are inserted into the corresponding slots. The segment coil projecting from the slot has an exposed conductor part and a covered conductor part covered with an electrical insulation film. The exposed conductor part is arranged at the distal end side from the covered conductor part of the segment coil. The segment coils are connected together through the exposed conductor parts thereof projecting from the slots. The exposed conductor part has a thickness T2 thinner than a thickness T1 of the covered conductor part. A step part is formed at a position of the stator core side, adjacent to the exposed conductor part of the segment coil. The step part and the covered conductor part are covered with the electrical insulation film continuously from the stator core side of the covered conductor part.