stator bar
Stator bars are the core conductive components installed inside the slots of the stator iron core for large & medium high-voltage generators and motors. Assembled from copper conductors and multi-layer insulation systems, dozens of stator bars are embedded into the stator core to form the complete stator winding.
They realize mutual conversion between electric energy and magnetic field, carry rated operating current, and withstand high voltage, temperature rise and mechanical vibration during operation.
Conductor CoreConsists of stacked glass-fiber covered flat copper wires with a 360° transposition design to reduce eddy current loss and heat generation. Wire ends are deburred to prevent insulation damage.
Inter-turn InsulationWrapped with epoxy mica tape to isolate voltage between internal turns and avoid inter-turn short circuits.
Main InsulationMulti-layer wrapped mica tape serves as the primary high-voltage resistant barrier for straight sections and ends. Extra insulation reinforcement is applied at bifurcation gaps to eliminate weak insulation points.
End Corona Shielding SystemGraded low-resistance & high-resistance corona protection tapes plus epoxy glass tapes are adopted to smooth electric field distribution, prevent corona discharge caused by air ionization under high voltage, and delay insulation aging.
New specifications require trial production and full performance testing before mass manufacturing. All raw insulating materials are subject to incoming quality inspection. After wrapping all insulation and anti-corona layers, bars undergo integral hot pressing & curing inside molds to achieve void-free, compact insulation structure for reliable electrical performance.
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