Stator Winding Coolant Channels Using Foam-Layer Slot Insulation
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Solution Overview
Problem
Existing dynamoelectric machines face challenges in achieving sufficient cooling performance due to the limitations of coolant access to conducting wires, particularly when varnish impregnation is omitted or used, leading to insufficient gaps between wires and reduced cooling efficiency.
Innovation Solution
The use of self-fusing conducting wires with insulating paper having a foam layer, which forms gaps between the wires to create a coolant channel, allowing effective cooling without varnish impregnation, and additional fixed members for stable winding fixation and vibration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a winding is impregnated with varnish to fix it in the slot, then the winding can be securely fixed, but gaps between conducting wires are reduced and cooling performance deteriorates
Solution Approach 1:
The patent extracts the fixation function from varnish impregnation and assigns it to a dedicated fixing member (resin layer or mechanical fixture) placed in the slot opening. This separation allows the winding to remain loose internally, maintaining gaps for coolant flow while achieving secure fixation externally through the dedicated fixing member
Solution Approach 2:
The patent introduces a fixing member as an intermediary element between the winding and the slot structure. This intermediary component provides the fixation function without requiring varnish impregnation of the winding itself, thereby preserving the gaps between conducting wires for effective cooling
2Ease of manufacture
If self-fusing wire is used to omit varnish impregnation, then manufacturing is simplified, but gaps between conducting wires are insufficient and cooling performance deteriorates
Solution Approach 1:
The patent modifies the physical state of the insulating material by using a foam layer that transitions from a compressed state during assembly to an expanded state after curing. This parameter change creates sufficient gaps between conducting wires for coolant flow while maintaining the simplicity of self-fusing wire construction
3Ease of manufacture
If insulating paper without foam layer is used, then manufacturing is simpler, but winding fixation becomes unstable and coolant channel uniformity deteriorates
Solution Approach 1:
The patent employs a foam layer within the insulating paper, utilizing its porous structure to provide both fixation capability and coolant channel formation. The foam's cellular structure creates uniform gaps between conducting wires when expanded, ensuring consistent coolant flow paths while maintaining manufacturing simplicity
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 configuration ensures efficient cooling by allowing direct coolant access to conducting wires, minimizing coolant channel non-uniformity, and providing stable winding fixation and durability even under high vibrations.
Implementation Method 1
the insulating paper has a foam layer... when the foam layer is foamed, the winding in the slot is pressed
Implementation Method 2
a coolant passes through only a space provided in a flank of a winding... a coolant channel is formed between the conducting wires of the winding
Data Source
AI summary
A dynamoelectric machine includes: a winding formed of a bundle of conducting wires; a stator core including a slot in which the winding is disposed; and an insulating paper disposed between the stator core and the winding in the slot, wherein the conducting wires have a self-fusing property, the insulating paper has a foam layer, and a coolant channel is formed between the conducting wires of the winding.