Three-Wall Potting Tray for Stator Winding Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric machines lack optimal protection for their components, particularly the switching rings and stator windings, while also requiring complex manufacturing processes.
Innovation Solution
The design incorporates a potting tray with a three-walled structure, including a middle wall, where the potting compound is filled to embed switching rings and stator windings, and uses a two-component potting tray with a soft component for sealing and a hard component for support, simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional potting tray without a middle wall is used, then the structure is simple, but the protection of switching rings and stator windings is insufficient
Solution Approach 1:
The potting tray is divided into three walls: outer wall, middle wall, and inner wall, creating separate filling chambers. This segmentation allows the potting compound to be contained and directed to specific areas, ensuring complete embedding of switching rings and stator windings while maintaining a manageable structure.
Solution Approach 2:
The middle wall is positioned between the outer wall and inner wall, creating a nested structure where the filling chamber is formed between these walls. This nested arrangement allows the potting compound to be contained in a specific chamber that directly surrounds the components needing protection.
2Reliability
If a separate seal is used in the potting tray, then sealing is reliable, but the number of parts and manufacturing complexity increase
Solution Approach 1:
The sealing function is merged into the middle wall itself through the elastic outer surface layer. This integration eliminates the need for separate seal components while maintaining reliable sealing against leakage, as the elastic layer conforms to the stator bushing and prevents potting compound from escaping.
Solution Approach 2:
The middle wall serves multiple functions: it provides structural support, creates the filling chamber, and simultaneously provides sealing through its elastic outer surface layer. This multi-functionality reduces the overall number of parts needed in the potting tray assembly.
3Reliability
If the potting compound is filled to completely embed switching rings, then protection is optimal, but material usage increases
Solution Approach 1:
The middle wall extracts and contains the potting compound within a defined filling chamber, preventing unnecessary material usage. The chamber is sized to provide exactly the amount of compound needed to embed the switching rings and stator windings, eliminating waste while ensuring complete protection.
Solution Approach 2:
The potting compound is applied locally within the filling chamber created by the middle wall, concentrating the material where it is most needed around the switching rings and stator windings. This localized application ensures optimal protection while minimizing overall material usage.
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
The invention relates to an electric machine (1) comprising a stator bushing (2), a potting tray (100), a potting compound (101), and a stator (4), wherein the potting tray (100) comprises an annular base (102), a first circumferential outer wall (103), and a second circumferential inner wall (104). The potting tray (100) further comprises a third, circumferential middle wall (105) between the outer wall (103) and the inner wall (104), wherein the potting compound (101) is contained in a filling chamber (106), and wherein the filling chamber (106) is formed between the middle wall (105) and the inner wall (104).