Motor Stator Winding Separation by Controlled Heating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods struggle to efficiently separate windings from electric motor stators used in vehicles due to strong adhesive forces caused by varnish impregnation, leading to difficulties in recycling and material contamination.
Innovation Solution
A winding separation method involving heating the electric motor stator to a temperature above the heat-resistant temperature of insulating paper but below the glass transition temperature of the coating, allowing for easy extraction of the winding while maintaining insulating properties and reducing adhesive forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional separation methods are used on electric motor stators with strong varnish bonding, then the winding can be separated, but the separation process becomes extremely difficult and time-consuming
Solution Approach 1:
The patent applies thermal energy to change the temperature parameter of the varnish, transforming it from a solid adhesive state to a softened state where its adhesive properties are reduced. This parameter change allows the winding to be separated easily without excessive force or time, directly resolving the contradiction between ease of separation and separation time.
Solution Approach 2:
The patent utilizes the phase transition of the varnish from solid to softened state through heating. By controlling the temperature to reach the glass transition temperature range, the varnish undergoes a phase change that reduces its bonding strength, enabling efficient winding separation while preventing damage to the stator core and winding.
2Productivity
If crushing method is used to dismantle the stator, then the stator can be quickly dismantled, but copper and iron materials become mixed requiring low-grade recycling
Solution Approach 1:
The patent segments the dismantling process into distinct stages: first heating and separating the winding from the stator core, then independently processing the stator core. This segmentation allows copper winding material and iron stator core material to be separated and recycled independently, maintaining high material purity while achieving efficient dismantling through the heated separation step.
3Ease of manufacture
If excessive heating is applied to separate the winding, then the adhesive force is reduced, but the insulating coating on the winding may be damaged
Solution Approach 1:
The patent precisely controls the temperature parameter during heating, maintaining it within the range of 80°C to 120°C, which corresponds to the glass transition temperature range of the varnish. This controlled parameter change softens the varnish for easy separation while staying below the temperature that would damage the insulating coating, thus resolving the contradiction between ease of separation and reliability of insulating properties.
Solution Approach 2:
The patent replaces mechanical force with thermal energy for the separation process. By using controlled heating instead of excessive mechanical force, the varnish is softened through thermal energy, enabling easy separation without applying mechanical stress that could damage the insulating coating, thereby maintaining both ease of separation and reliability.
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 method enables efficient separation of windings from electric motor stators, facilitating recycling and reducing material contamination, and allows for the use of energization for heating, improving the recycling process and reducing energy consumption and carbon dioxide generation.
Implementation Method 1
a heating step of heating the electric motor stator
Implementation Method 2
a heat-resistant temperature of the insulating paper is lower than a glass transition temperature of the coating
Implementation Method 3
a heat-resistant temperature of the insulating paper is lower than a glass transition temperature of the coating
Data Source
AI summary
A winding separation method of separating a winding from an electric motor stator that includes a stator core and a coil attached to the stator core and has insulating paper between the winding of the coil and the stator core, which the winding is covered with a coating having insulating properties, which method includes: a heating step of heating the electric motor stator; a cutting step of cutting a predetermined welded portion of the electric motor stator and a portion of the winding; and an extraction step of extracting the winding from the stator core, in which a heat-resistant temperature of the insulating paper is lower than a glass transition temperature of the coating of the winding.