Stator Winding Insulation Structure for Electromagnetic Motor
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Solution Overview
Problem
Existing winding insulation structures for electromagnetic motors face challenges in ensuring an adequate electrical insulation distance between windings and stator iron cores, particularly in small motors, due to insufficient gap distances and difficulties in inserting insulation sheets, which complicates the winding process and can lead to insulation member breakage and winding area constraints.
Innovation Solution
The formation of insulation sheet insertion portions between the stator iron core and insulation members on the slot opening side allows easy insertion of insulation sheets, maintaining even thickness of the insulation members and simplifying the winding process without requiring machining, thus securing an electrical insulation distance with a straightforward structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a step is provided in the insulation member to form a gap for inserting the insulation sheet, then the insulation sheet can be easily inserted, but the insulation member becomes difficult to mold and is easily broken due to the small thickness at the step portion
Solution Approach 1:
The insulation structure is divided into two separate components: the insulation member (molded piece) and the insulation sheet. The insulation sheet is inserted into a groove formed on the insulation member, separating the functions of structural support (insulation member) and electrical insulation (insulation sheet). This segmentation allows the insulation member to maintain uniform thickness for easy molding while the insulation sheet provides the necessary insulation gap.
Solution Approach 2:
The groove on the insulation member serves as an intermediary structure that accommodates the insulation sheet. Instead of creating a step that reduces thickness, the groove provides a dedicated space for the insulation sheet while maintaining the overall structural integrity and uniform thickness of the insulation member.
2Reliability
If both end portions of the insulation member are bent toward the inside of the slot to secure insulation distance, then the electrical insulation distance is improved, but the winding area is reduced and the winding operation becomes difficult
Solution Approach 1:
The insulation function is segmented between the insulation member (提供基本绝缘和结构支撑) and the insulation sheet (提供额外的绝缘距离). This segmentation allows the insulation member to maintain a simple, non-bent structure that does not interfere with winding operations, while the insulation sheet provides the necessary insulation distance.
Solution Approach 2:
Instead of bending the insulation member in the radial direction (which reduces winding area), the insulation sheet is inserted into a groove, adding insulation thickness in the axial direction. This dimensional change provides the required insulation distance without compromising the winding area or operation.
3Manufacturing precision
If manual placement of the insulation sheet is required, then the insulation sheet can be positioned, but the placement process requires time and reduces productivity
Solution Approach 1:
The groove for accommodating the insulation sheet is pre-formed on the insulation member during the molding process. This preliminary action ensures that the insulation sheet can be easily inserted and positioned correctly without requiring manual adjustment or complex positioning mechanisms, thereby improving both precision and productivity.
Solution Approach 2:
The groove structure on the insulation member provides self-aligning and self-positioning features for the insulation sheet. When the insulation sheet is inserted into the groove, it automatically assumes the correct position, eliminating the need for manual positioning and reducing the time required for this operation.
Data Source
AI summary
A winding insulation structure of a stator of an electromagnetic motor is provided, in which windings are wound inside slots of a stator iron core of the electromagnetic motor formed of a stator and a rotor with an insulation member therebetween, and in which an insulation sheet insertion portion for inserting an insulation sheet is formed between the stator iron core and the insulation member on a slot opening portion side of the stator iron core.