Stator Winding Retention via Offset Metal Sheet Notch Closure
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Solution Overview
Problem
Rotary electrical machine stator windings are not well compacted and secured in notches, leading to increased space occupation and risk of collision with the rotor, with existing solutions either damaging the wire or reducing performance.
Innovation Solution
A stator design with notches that utilize offset metal sheets to form closure elements, allowing for compact and secure winding retention without damaging the wire, using tools with radial dimensions greater than the notch width for progressive deformation and self-centering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional winding retention methods are used, then windings are secured in notches, but windings are not well compacted and occupy increased space
Solution Approach 1:
The notch closure element is formed in advance by offsetting adjacent metal sheets before winding insertion. This preliminary structural preparation creates a pre-configured retention mechanism that efficiently secures windings while minimizing space occupation.
Solution Approach 2:
The stator body is segmented into multiple metal sheets that can be independently offset to form closure elements. This segmentation allows precise control over winding retention and space optimization without affecting the entire stator structure.
2Volume of moving object
If existing compacting solutions are applied, then windings are compacted, but the wire is damaged
Solution Approach 1:
The notch closure element acts as an intermediary structure between the winding and the stator body. It provides mechanical retention and compacting force through controlled metal sheet offsetting, avoiding direct harmful contact with the wire while achieving effective compactness.
3Volume of moving object
If existing compacting solutions are applied, then windings are compacted, but performance is reduced
Solution Approach 1:
The offsetting of metal sheets is applied locally at specific notches where closure elements are needed, rather than uniformly across the entire stator. This localized approach achieves necessary compactness while preserving electrical performance in other critical areas.
4Reliability
If metal sheets are offset to form closure elements, then winding retention is improved, but stator structure complexity increases
Solution Approach 1:
The metal sheets serving as stator body components are given a dual function: they provide structural support and, when offset, form closure elements for winding retention. This multi-functionality reduces overall structure complexity by eliminating the need for separate retention components.
Data Source
AI summary
A stator of a rotary electrical machine has a stator body formed by a stack of metal sheets. The stator body is delimited by inner and outer radial surfaces. Notches in the stator body extend axially. Each notch has a notch base and a notch opening, and the notch opening is on the side of the inner radial surface. A stator winding is supported by the stator body, and the winding has a plurality of winding parts. Each part is accommodated in one of the notches. Each of the notches at the notch opening has a closure element. Each winding par in a notch is retained between the notch base and the closure element. The closure elements are formed by offsetting at least one of the metal sheets of an adjacent notch in the direction of the notch.