Potting and insulation system for a concentrated coil soil stator
An assembly for an electric machine including a core with a plurality of teeth extending radially inward from the core, the plurality of teeth defining a plurality of slots for receiving coils, a plurality of coils, each coil wrapping around a respective tooth, a separator in one of the slots including a first leg joined at an angle to a second leg for separating adjacent coils within the slot, an insert between the first leg and the second leg for at least partially filling a space between the first leg and the second leg, and a potting filling space within the slot between the separator, the plurality of coils, and the insert.
1. An assembly for an electric machine comprising:
a core having a plurality of teeth extending radially inward from the core, the plurality of teeth defining a plurality of slots for receiving coils;
a plurality of coils, each coil wrapping around a respective tooth;
a separator in one of the slots including a first leg joined at an angle to a second leg for separating adjacent coils within the slot, wherein the first leg is connected to a second leg of an adjacent separator by a cord;
an insert between the first leg and the second leg for at least partially filling a space between the first leg and the second leg; and
a potting filling space within the slot between the separator, the plurality of coils, and the insert.
2. The system of claim 1 , wherein the separator is “V” shaped.
3. The system of claim 1 , wherein the first leg and the second leg each contact a wall of the slot.
4. The method of claim 1 , wherein the separator is electrically isolating.
5. The system of claim 1 , wherein the insert is deformable.
6. The system of claim 1 , wherein the insert includes aramid felt.
7. The system of claim 1 , wherein the insert assumes a shape of the space.
8. The system of claim 1 , wherein the insert includes a thermal sensor.
9. The system of claim 1 , wherein the potting includes epoxy.
10. The system of claim 1 , wherein the separator and the insert absorb a portion of the potting.
11. The system of claim 1 , wherein a first side of the first leg contacts the coils and a second side of the first leg contacts the insert.
12. The system of claim 1 , wherein a liner covers a wall of the slot.
13. The system of claim 1 , wherein each of the plurality of slots includes a separator, an insert, and a potting.
14. An assembly for an electric machine comprising:
a core having a plurality of teeth extending radially inward from the core, the plurality of teeth defining a plurality of slots for receiving coils;
a plurality of coils, each coil wrapping around a tooth;
a deformable “V” shaped separator including a first leg joined at an angle to a second leg for separating adjacent coils;
a deformable insert between the first leg and the second leg for expanding a space between the first leg and the second leg, wherein the first leg is connected to a second leg of an adjacent separator by a cord;
a thermal sensor located within the deformable insert; and
an epoxy potting covering the plurality of coils, and being absorbed by the deformable “V” shaped separator and the deformable insert.
15. A method for insulating coils comprising:
placing a separator including a first leg joined at an angle to a second leg in a slot between adjacent teeth and adjacent coils forming a space between the legs of the separator and a wall of an electric machine;
inserting an insert into the space;
potting the coils, the separator, and the insert and
connecting the first leg to a second leg of an adjacent separator by a cord.
16. The method of claim 15 , wherein epoxy is used for potting.
17. The method of claim 16 , wherein the separator and the insert are saturated with epoxy.