Trapezoid Segmented Stator Coil for Compact Dynamo-Electric Machine
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Solution Overview
Problem
The challenge in downsizing dynamo-electric machines for automobiles is to stably provide an insulation distance in limited spaces while reducing the height of coil ends, which is essential for efficient operation in narrow installations.
Innovation Solution
The dynamo-electric machine incorporates a stator with a stator iron core having slots for a stator coil, where segment coils with a rectangular cross-section are connected and shaped in a U-form, allowing for increased coil width away from edges, and covered with an insulating film to maintain reliable insulation properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the height of coil ends is reduced to downsize the dynamo-electric machine, then the machine size is reduced, but it becomes difficult to stably provide an insulation distance
Solution Approach 1:
The patent applies local quality by making the coil width variable along the height direction - the coil width is increased in the lower portion (away from opposed edges) while maintaining standard width in upper portions. This localized dimensional variation allows the coil ends to achieve compact height while preserving sufficient insulation distance in critical areas, thus resolving the contradiction between downsizing and insulation reliability.
Solution Approach 2:
The patent introduces asymmetry in the coil end structure by creating an uneven width distribution - adjacent segment coils have different widths at different heights, with at least one coil having increased width in its lower portion. This asymmetric design optimizes the insulation distance configuration without requiring uniform increases in all dimensions, enabling compact overall size while maintaining reliable insulation.
2Length of moving object
If the coil ends are downsized for narrow space installation, then the machine fits better in limited space, but providing stable insulation distance becomes problematic
Solution Approach 1:
The patent applies local quality by making the coil width variable along the height direction - the coil width is increased in the lower portion (away from opposed edges) while maintaining standard width in upper portions. This localized dimensional variation allows the coil ends to achieve compact height while preserving sufficient insulation distance in critical areas, thus resolving the contradiction between downsizing and insulation reliability.
Solution Approach 2:
Instead of increasing insulation distance uniformly in the vertical dimension (which would increase coil end height), the patent transitions to utilizing the horizontal dimension by increasing coil width in specific lower portions. This dimensional shift allows insulation distance to be maintained through lateral expansion rather than vertical expansion, achieving compact height while preserving insulation reliability.
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 configuration effectively downsizes the coil ends, enhances insulating properties, and maintains reliable electrical performance, suitable for both motor and generator functions in compact automotive applications.
Implementation Method 1
alternating-current power is supplied to a stator coil to generate a rotating magnetic field, and then a rotator is rotated with this rotating magnetic field
Implementation Method 2
The stator coil is provided with an insulating film
Data Source
AI summary
There is provided a dynamo-electric machine that can provide excellent insulating properties by downsizing coil ends. A dynamo-electric machine includes a stator and a rotator. The stator has a stator iron core formed with a plurality of slots arranged in a circumferential direction, and a stator coil inserted into the slots of the stator iron core. The rotator is rotatably disposed on the stator iron core with a predetermined gap. The stator coil is provided with an insulating film. The stator coil includes a main coil and a lead wire with an alternating current terminal. The main coil has a plurality of segment coils connected to one another. The segment coil is a conductor in a rectangular cross section formed in advance in a nearly U-shape. The lead wire is led from the slot. The tip end of the segment coil is formed in a trapezoid cross section.