Stator Winding Axial Dimension Reduction via Localized Conductor Exposure
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Solution Overview
Problem
The existing stator windings for rotating electric machines have a large axial dimension due to the entirety of the terminal portion forming a conductor exposure portion, which increases the overall size of the machine.
Innovation Solution
The stator winding design includes a conductor exposure portion and an insulating film remainder portion at the terminal ends, where the conductor is exposed only at specific portions and covered by the insulating film elsewhere, with a joining portion formed by laser radiation between the terminal ends, reducing the axial dimension by using an overlay alloy layer with a lower melting point than the conductor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the entirety of the terminal portion forms the conductor exposure portion, then the joining portion can be connected to the terminal portion, but the dimension of the stator winding in the axial direction becomes large
Solution Approach 1:
The terminal portion is divided into two functional regions: a conductor exposure portion where the insulating film is removed to enable electrical connection, and an insulating film remainder portion where the insulating film is retained to provide insulation. This local differentiation allows the joining portion to be connected at the exposed conductor region without requiring the entire terminal portion to be exposed, thereby reducing the axial dimension while maintaining manufacturing feasibility.
2Ease of manufacture
If the insulating film is removed from the entire terminal portion, then the conductor can be fully exposed for joining, but the insulating film may be damaged during the joining process
Solution Approach 1:
The insulating film is selectively removed only at the conductor exposure portion where joining is required, while the insulating film remainder portion retains the insulating film to protect the conductor. This localized approach ensures that the conductor is adequately exposed for joining operations while preserving the insulating film's integrity in regions where it provides protective functionality.
Solution Approach 2:
By retaining the insulating film in the insulating film remainder portion, the structure provides a protective buffer that prevents damage to the conductor and insulating film during the joining process. The insulating film acts as a cushioning layer that absorbs mechanical stresses and protects the underlying conductor from potential damage during joining operations.
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 design reduces the axial dimension of the stator winding, allowing for downsizing of the rotating electric machine, minimizing conductor usage, and reducing production costs while preventing damage to the insulating film and optimizing the joining process.
Implementation Method 1
a joining portion formed by laser radiation between the terminal ends
Implementation Method 2
using an overlay alloy layer with a lower melting point than the conductor
Data Source
AI summary
A stator winding for a rotating electric machine includes: a plurality of lead wires each including a conductor and an insulating film provided on side surfaces of the conductor; and a joining portion configured to join terminal portions of the plurality of lead wires to each other. The plurality of lead wires each includes: a conductor exposure portion provided at a portion of the terminal portion at which the terminal portions of the plurality of lead wires face each other, has the conductor exposed thereat, and has the joining portion connected thereto; and an insulating film remainder portion, provided at a portion of the terminal portion of the lead wire excluding the conductor exposure portion, and has the conductor covered with the insulating film, and a portion of the insulating film in the insulating film remainder portion is provided in a periphery of the joining portion.