Stator Winding Insulation via Head Interposition
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Solution Overview
Problem
Conventional stator designs for electric rotating machines in automotive vehicles face challenges in ensuring adequate electrical insulation between coil ends without increasing the size or material cost of the stator winding, leading to potential electrical discharge and mountability issues.
Innovation Solution
The stator design features an annular core with slots and conductor segments bent into U- or V-shapes, where the legs of the segments are inserted through slots from opposite directions, allowing the heads to interpose between adjacent coil end pairs, ensuring sufficient insulation without the need for lengthy base portions, thus reducing the overall height and material requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the coil ends are arranged radially in line to ensure compact structure, then the stator size is reduced, but the electrical insulation interval between adjacent coil ends becomes insufficient leading to electrical discharge
Solution Approach 1:
The patent transitions from a single radial arrangement to a two-dimensional arrangement by introducing circumferential spacing between coil ends. Instead of merely radial positioning, coil ends are distributed across different circumferential positions, creating an interval that prevents electrical discharge while maintaining compact overall dimensions.
Solution Approach 2:
The patent employs asymmetric arrangement of coil ends where adjacent coil ends are positioned at different radial distances from the stator core center. This asymmetric positioning creates natural insulation intervals without requiring uniform radial spacing, allowing compact design while ensuring electrical isolation.
2Reliability
If slant base portions are added to coil ends to increase insulation interval, then electrical insulation is improved, but the overall height and material cost of the stator winding increases
Solution Approach 1:
Instead of extending coil ends axially (adding height), the patent uses circumferential and radial positioning to create insulation intervals. The spacing is achieved through dimensional distribution in the radial-circumferential plane rather than axial extension, avoiding increased overall height.
Solution Approach 2:
The patent changes the positioning parameters of coil ends by controlling their radial distances and circumferential angles. By adjusting these parameters, sufficient insulation intervals are achieved without modifying the axial dimensions or adding extensive base portions, thereby reducing material requirements.
3Reliability
If adequate insulation intervals are maintained between coil ends, then electrical discharge is prevented, but the stator size and material requirements increase
Solution Approach 1:
The patent achieves insulation through spatial distribution in radial and circumferential dimensions rather than through axial extension. This allows adequate insulation intervals to be created using the existing material length, reducing the need for additional conductor material while preventing electrical discharge.
Solution Approach 2:
By optimizing the radial distance parameters and circumferential angle parameters of coil end positions, the patent achieves sufficient insulation intervals with minimal material. The parameter optimization allows compact winding design that prevents electrical discharge without excessive material consumption.
Data Source
AI summary
A stator for an electric rotating machine is equipped with a stator winding made up of a plurality of conductor segments. Each of the conductor segments has a head and two legs. The legs are inserted through their respective slots formed in a stator core, so that each of the conductor segments has leg ends protruding from either one of opposed end surfaces of the stator core and the head thereof protruding from the other end surface. Radially adjacent two of the leg ends are provided as a coil end pair to be welded. At least one of the heads is interposed between adjacent two of the coil end pairs, thereby ensuring a distance between the two adjacent coil end pairs which is great enough to provide a required degree of electric insulation between the coil end pairs when the leg ends of the conductor segments are welded electrically.