Stator Winding Insulation for Compact Rotating Machines
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In rotating electrical machines, ensuring a stable insulating distance within the narrow space constraints of automobile applications is challenging, particularly for segment coils, which affects the reliability of the stator and overall machine performance.
Innovation Solution
A stator design featuring a winding with a molten metal junction and a covering material with a bending part that contacts the winding, along with a stator coil structure using U-shaped conductors and a bellows-shaped enamel coat at the welds to maintain insulation and reduce coil end height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the height of the end coil is reduced to achieve downsizing, then the space utilization is improved, but the insulating distance becomes insufficient
Solution Approach 1:
The patent introduces a bellows-shaped enamel coat that extends in the axial direction, adding dimensional complexity to the insulation structure. This allows the insulating distance to be maintained in the axial dimension while the radial dimension (coil height) is reduced, effectively resolving the contradiction between downsizing and insulation reliability
Solution Approach 2:
The bellows-shaped enamel coat acts as a flexible insulating structure that can accommodate spatial constraints. The bellows shape provides extended insulation path length within a compact volume, enabling sufficient insulating distance without increasing the overall coil end height
2Ease of operation
If segment coils are connected via weld in narrow space, then the electrical connection is achieved, but the insulating reliability is compromised
Solution Approach 1:
The patent applies different insulation structures to different locations: the bellows-shaped enamel coat is specifically positioned at the weld area of segment coils, providing enhanced local insulation where the welding connection occurs. This localized approach maintains insulating reliability at the critical connection point without affecting overall coil design
Solution Approach 2:
The bellows-shaped enamel coat serves as an intermediary insulating layer between the welded segment coil terminals and surrounding conductive parts. This intermediate structure ensures electrical isolation is maintained even in the constrained space where welding connections are necessary
Data Source
AI summary
A component for a rotating electrical machine includes a stator, a winding, and a covering material. The stator has a stator core with a plurality of slots. The winding is inserted into one slot. The covering material covers the winding. The winding has a molten metal junction. The covering material has a non-bending part and a bending part. The bending part has a contact area that is smaller than an area between the non-bending part and the winding. The bending part is provided between the molten metal junction and the portion of the winding inserted in the one slot.