Rotary Electric Machine Stator Insulation Welding Heat Shield
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Solution Overview
Problem
The existing methods for manufacturing rotary electric machines face a challenge in maintaining insulation reliability between stator coils, as the insulating members can be burnt and carbonized during welding processes.
Innovation Solution
A method involving an interposed member with fiber or film material is used, positioned between coil end portions and the insulating member, which includes through holes for inserting coil end portions and is disposed centrally between adjacent coil ends to absorb radiant heat and prevent dielectric breakdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating member is used to protect stator wiring from heat, then insulation reliability is improved, but the insulating member itself is burnt during welding
Solution Approach 1:
The interposed member serves as a thermal shield and intermediary layer between the welding zone and the insulating member. It absorbs the radiant heat before it can reach the insulating member, thereby protecting the insulating member from thermal damage while maintaining its insulation function.
Solution Approach 2:
The interposed member is positioned in advance before welding occurs, creating a protective barrier that cushions the insulating member against upcoming thermal exposure. This preemptive measure ensures the insulating member is already protected when the welding heat is generated.
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 approach effectively suppresses the reduction of insulation reliability by absorbing heat and reducing the risk of burn and breakage, enhancing durability and preventing dielectric breakdown during welding.
Implementation Method 1
an interposed member 600...which absorbs radiant heat and prevents dielectric breakdown
Data Source
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AI summary
An object of the present invention is to suppress reduction of insulation reliability between stator coils. A method of manufacturing a rotary electric machine according to the present invention is a method of manufacturing a stator including an insulating member intervening between a plurality of coil end portions each protruding from a stator core, the method including: a first step of disposing an interposed member to cover part of the insulating member between the plurality of coil end portions; and a second step of welding part of each of the plurality of coil end portions.