Straight Tooth Coil Insulation Structure for Rotating Machines
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Solution Overview
Problem
Conventional coil insulation structures for rotating machines face challenges in achieving optimal space filling factors and insulation effects due to the limitations of stator groove openings, which restrict the winding process and require excessive operation space for automatic winding equipment.
Innovation Solution
A coil insulation structure featuring an iron core with straight tooth portions and 'Π'-shaped insulation members, where second insulation members with protruding insertion sheets are used to facilitate coil winding insertion and maximize space filling, and a sealant is applied to encapsulate the windings, enhancing insulation and product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a shoe portion is added to the stator tooth to reduce cogging torque, then the stator groove opening size is reduced, but the winding process becomes more difficult and requires automatic winding equipment with excessive operation space
Solution Approach 1:
The insulation structure is divided into multiple components: first insulation members placed inside grooves, second insulation members placed at groove openings, and third insulation members for additional protection. This segmentation allows each component to perform its specific function optimally while maintaining ease of manufacturing.
Solution Approach 2:
The insulation members are pre-positioned in the grooves before coil winding insertion. This preliminary action ensures proper insulation is already in place, facilitating the winding process and eliminating the need for excessive operation space for automatic winding equipment.
2Ease of operation
If automatic winding equipment is used to directly wind enameled wire around stator tooth, then sufficient operation space is provided, but the groove space is not used optimally resulting in lower space filling factor
Solution Approach 1:
Coil windings are pre-wound outside the iron core and then inserted into the grooves. This preliminary winding approach allows for optimized coil geometry and maximum space utilization within the grooves, achieving higher space filling factors compared to direct winding around stator teeth.
Solution Approach 2:
Instead of winding coils directly around stator teeth from the inside, the invention inverts the process by winding coils externally and inserting them into the grooves. This inversion enables better space utilization and higher space filling factors while still providing sufficient operation space for winding equipment.
3Device complexity
If coil windings are inserted directly into grooves without additional insulation components, then the structure is simpler, but the insulation effect is insufficient and inner layer thickness cannot be ensured
Solution Approach 1:
The insulation system is segmented into first insulation members for basic groove insulation, second insulation members for groove opening protection and inner layer thickness control, and third insulation members for additional insulation enhancement. This segmentation provides comprehensive insulation protection while maintaining a manageable structure.
Solution Approach 2:
Different insulation members are placed at specific locations: first insulation members inside grooves for local insulation, second insulation members at groove openings for edge protection and thickness control, and third insulation members for additional local reinforcement. This local quality approach ensures insulation effectiveness throughout the structure.
Data Source
AI summary
A coil insulation structure for a rotating machine provided in the present invention is based on a conventional insulation technology. In particular, tooth portions of an iron core in which coil windings are inserted have a straight tooth structure without a shoe portion, and a component with an insulation effect is further added at a position of an opening of a groove in which the coil winding is located, so that an insulation effect is improved, and at the same time an added insulation component is used to ensure a thickness and a size of an inner layer located at a position adjacent to an air gap of a motor when the coil winding is encapsulated, thereby improving product quality.