Stator Varnish Impregnation Using Outer Support and Inner Heating

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Solution Overview

Problem

Existing varnish impregnation apparatuses face issues with varnish adhesion to supports and inefficient heating of stator coils, leading to extended heating times and reduced productivity in varnish impregnation processes.

Innovation Solution

A varnish impregnation apparatus that supports the stator coil with its axial direction in a horizontal direction, using a radially outer grasping ring to prevent adhesion and a heater disposed in the stator core's cavity to efficiently heat the stator from the radially inner side, combined with a varnish dropping device to ensure uniform varnish application and curing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the stator is supported from the radially inner side by a workpiece rotary shaft inserted into the cavity portion, then the stator can be rotated for varnish impregnation, but the heating device cannot be disposed in the cavity portion and the coil cannot be heated efficiently

Engineering Contradiction:

Improvestator rotation capabilityVSAvoidheating efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

Instead of supporting the stator from the radially inner side (cavity portion), the invention supports the stator from the radially outer side using a support that grasps the outer peripheral surface. This inversion resolves the conflict by allowing the heating device to be disposed in the cavity portion for efficient heating while maintaining stator rotation capability through the outer side support structure.

Inventive Principle:

Principle #13The other way round (Inversion)

2Ease of operation

If the stator is supported from the radially inner side, then the stator can be rotated during varnish impregnation, but varnish overflowing from the stator adheres to the support

Engineering Contradiction:

Improvestator rotation during impregnationVSAvoidvarnish adhesion to support

Core Design Contradiction:

Ease of operationVSObject-generated harmful factors

Solution Approach 1:

The support is repositioned from the radially inner side to the radially outer side, grasping the outer peripheral surface of the stator. This inversion prevents varnish adhesion to the support while maintaining the ability to rotate the stator during varnish impregnation, as the support is now positioned outside the varnish application zone.

Inventive Principle:

Principle #13The other way round (Inversion)

3Temperature

If the stator is placed on a reception stand with vertical axis for induction heating, then the stator can be heated from the radially inner side, but varnish adheres to the outer peripheral surface during impregnation

Engineering Contradiction:

Improvestator heating capabilityVSAvoidvarnish adhesion to outer surface

Core Design Contradiction:

TemperatureVSObject-generated harmful factors

Solution Approach 1:

The stator support orientation is inverted from vertical (reception stand) to horizontal (radially outer side support). This allows the heating device to access the cavity portion for efficient heating while the horizontal orientation with outer-side support prevents varnish from adhering to the outer peripheral surface during impregnation.

Inventive Principle:

Principle #13The other way round (Inversion)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution prevents varnish adhesion to the support while efficiently heating the stator coil, reducing heating time and improving productivity in varnish impregnation, allowing for simplified equipment design and cost reduction.

Implementation Method 1

a heater disposed in a cavity portion provided at an axial center of the stator core of the stator supported by the support to heat the stator from a radially inner side of the stator

Methodology Applied

Scientific EffectConduction heating: Conduction (thermal)

Implementation Method 2

a support that supports a stator, in which the stator coil is mounted to the stator core, with an axial direction of the stator directed in a horizontal direction while grasping a radially outer side of the stator, and that is rotationally driven by a rotary device to rotate the stator

Methodology Applied

Scientific EffectMechanical rotation:

Implementation Method 3

a varnish dropping device that drops the varnish toward a coil end portion of the stator which is rotated while being supported by the support

Methodology Applied

Scientific EffectGravity-driven dripping: Gravitation

Data Source

PatentUS10148158B2Varnish impregnation apparatus and varnish impregnation method

Publication Date: 2018.12.04 AISIN AW CO LTD

AI summary

A varnish impregnation apparatus that includes a support that supports a stator, in which the stator coil is mounted to the stator core, with an axial direction of the stator directed in a horizontal direction while grasping a radially outer side of the stator, and that is rotationally driven by a rotary device to rotate the stator; a varnish dropping device that drops the varnish toward a coil end portion of the stator which is rotated while being supported by the support; and a heater disposed in a cavity portion provided at an axial center of the stator core of the stator supported by the support to heat the stator from a radially inner side of the stator.