Stator Winding Insulating Paper Bonding for Packing Density

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Solution Overview

Problem

Existing methods for inserting coil wire into stator coil spaces in electric drives are time-consuming and costly, and fail to achieve the required electrical safety distance and packing density, leading to inefficiencies in motor performance and handling.

Innovation Solution

A method involving the insertion of insulating paper with protruding legs into the coil space, which are connected using heated stamp-shaped abutment sections coated with baking varnish to create a material bond, ensuring a secure and insulated coil wire placement with a safety distance of at least 2 mm, allowing for higher packing density and automated wire insertion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If pre-wound coils are manually inserted into the coil space, then the coil wire is protected against abrasion and electrical insulation is ensured, but the production process becomes extremely complex, time-consuming and cost-intensive

Engineering Contradiction:

Improveprotection against abrasion and electrical insulationVSAvoidproduction process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The protective and insulating function is extracted from the pre-wound coil structure itself and implemented separately through insulating paper that is inserted into the coil space before automated winding. This separates the protection function from the winding process, allowing automated insertion and winding without manual pre-assembly.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The insulating paper is inserted into the coil space in advance before the coil wire is wound. The insulating paper includes protruding sections that extend beyond the coil slots, providing pre-positioned protection and insulation. This preliminary action eliminates the need for post-winding protective measures and enables automated processing.

Inventive Principle:

Principle #10Preliminary action

2Power

If the maximum outer diameter of the rotor is increased to improve motor power, then the torque delivered by the electric motor increases, but the device size and handle circumference increase

Engineering Contradiction:

Improvemotor power and torqueVSAvoiddevice size and handle circumference

Core Design Contradiction:

PowerVSLength of stationary object

Solution Approach 1:

The invention changes the packing density parameter of the coil wire in the coil space. By achieving higher packing density through automated winding with insulating paper preparation, more coil wire can be accommodated in the same volume, increasing motor power without increasing the rotor diameter and thus maintaining compact device size.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If automated needle winding is used to insert coil wire directly into the coil space, then higher packing density and rapid winding are achieved, but the electrical safety distance and packing density requirements are not met

Engineering Contradiction:

Improvewinding speed and packing densityVSAvoidelectrical safety distance

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The insulating paper is inserted into the coil space before the automated winding process. The protruding sections of the insulating paper extend beyond the coil slots and provide pre-positioned electrical insulation. This preliminary action ensures that when automated needle winding inserts the coil wire, the required electrical safety distance is maintained without reducing winding speed or packing density.

Inventive Principle:

Principle #10Preliminary action

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 enhances the electrical safety and abrasion protection of the coil wire, achieves a higher packing density, and allows for a more compact motor design with increased performance, while reducing production costs and complexity.

Implementation Method 1

connecting the two insulating paper legs of an insulating paper inserted in a coil groove, these being connected to one another at least partially and at least in the region of the respective protruding sections. The step of connecting is carried out by means of a device for connecting, which has two stamp-shaped abutment sections which can be heated to produce a connection

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

Methodology Applied

Scientific EffectBaking varnish: Adhesive

Data Source

PatentEP2605385B1Method for winding the magnetic coils of a stator and stator

Publication Date: 2022.01.26 METABOWERKE

Figure 1~2
Figure 3
Figure 4a~4b

AI summary

The method involves inserting an insulating paper (30) in coil chamber such that two opposing legs of insulating paper are partially out of respective coil grooves in a direction perpendicular to a longitudinal axis (L) of a stator segment (12). A coil wire (20) is inserted in coil chamber. The projecting portions (32) of two opposing legs of insulating paper are interconnected and are connected with coil wire. Independent claims are included for the following: (1) two-pole stator; and (2) device for manufacturing stator.