Diamond coil stator with parallel paths and balanced winding arrangement

Abstract

Stator (10) for an electric machine, comprising: a core (12) containing a plurality of slots (32, 16); and a multiphase winding arrangement (20) positioned on the core (12), wherein each phase of the winding arrangement (20) comprises a plurality of parallel paths (52, 54, 56, 58) defining a plurality of poles (80), wherein each parallel path (52, 54, 56, 58) contains a plurality of coils (30) positioned on the core (12), each coil (30) being defined by coil legs and end windings (40), the coil legs comprising left legs (32a) and right legs (32b) extending through the slots (32, 16) of the core (12), and the left legs (32a) and right legs (32b) of each coil (30) being connected by first end windings (40a) at one end of the core (12) and second end windings (40b) at an opposite end of the core (12), wherein each pole (80) is associated with a pole slot set (86) consisting of several slots (32, 16), wherein each pole slot set (86) contains a left slot, a middle slot and a right slot, wherein for each pole slot set (86) legs for each parallel path (52, 54, 56, 58) extend through a slot (32, 16) of the pole slot set (86) such that conductors for all of the parallel paths (52, 54, 56, 58) of the phase of the winding arrangement (20) are maintained or secured in each pole slot set (86), wherein for each pole slot set (86) left legs (32a) of a first coil (30) are in an outer half of the middle slot and right legs (32b) of the first coil (30) are in an inner half of a left slot of a right adjacent pole slot set (80), wherein each of the multiple coils (30) are diamond- or rhomboid-shaped coils, wherein each parallel path (52, 54, 56, 58) further includes series connections (61) extending between sets of the plurality of coils (30), wherein each set of coils (30) comprises at least two adjacent coils (30), wherein the series connections (61) are positioned radially outwards from the first terminal windings (40a) at one end of the core (12), characterized in that that at least two of the series connections (61b) extending between two sets of the plurality of coils (30) run in such a crisscrossing manner that a coil position associated with each series connection (61) switches slot positions in an adjacent pole slot set (80), wherein the at least two intersecting series connections (61b) comprise a first series connection which intersects a second series connection, the first series connection extending between at least two adjacent coils (30) by two slot positions further than the second series connection, and wherein the first row connection extends one slot position further than the other row connections of the associated parallel path (52, 54, 56, 58).

Description

CROSS-REFERENCE TO RELATED REGISTRATIONS

[0001] This application claims priority over provisional US patent application No. 63 / 173,236, filed on April 9, 2021, the entire contents of which are incorporated herein by reference. AREA

[0002] The present disclosure relates to the field of electrical machines and in particular stator winding arrangements. BACKGROUND

[0003] Winding arrangements for stators, including winding arrangements with diamond- or rhomboid-shaped coils, are known. Electrical machines incorporating such winding arrangements are particularly suitable for certain applications, but improvements to such electrical machines would be advantageous. For example, it would be desirable to improve the electrical balance in such machines when the rotor / stator arrangement of the electrical machine is not perfectly concentric (e.g., due to manufacturing tolerances). Additionally, it would be advantageous to provide a winding arrangement for such an electrical machine in which all the conductors are suitably arranged within a limited area of ​​the electrical machine. US Patent 2008 / 0201935 A1 discloses a manufacturing method for a three-phase machine and a stator with a three-phase winding with two parallel paths per phase. SUMMARY

[0004] In at least one embodiment, a stator for an electric machine comprises a core defining a plurality of slots and a multiphase winding arrangement positioned on the core. Each phase of the winding arrangement contains a plurality of parallel paths defining a plurality of poles for the electric machine. Each parallel path contains a plurality of coils positioned on the core. Each coil is defined by coil legs and end turns. The coil legs comprise left legs and right legs extending through the slots of the core, with the left and right legs of each coil being connected by first end turns at one end of the core and second end turns at the opposite end of the core. Each pole of the electric machine is associated with a pole slot set consisting of multiple slots on the stator core.For each pole slot set, legs extend for each parallel path through a slot of the pole slot set, so that conductors for all of the parallel paths of the phase of the winding arrangement are maintained or secured in each pole slot set.

[0005] In at least one additional embodiment, a stator for an electric machine comprises a core defining a plurality of slots and a multiphase winding arrangement including coil connections. The winding arrangement is positioned on the core, with each phase of the winding arrangement comprising a plurality of parallel paths defining a plurality of poles for the electric machine. Each parallel path contains a plurality of coils positioned on the core and a plurality of coil connections extending between the plurality of coils. Each coil is defined by coil legs and end turns. The coil legs comprise left legs and right legs extending through the slots of the core. The left legs and right legs of each coil are connected by first end turns at one end of the core and second end turns at the opposite end of the core.Each pole of the winding arrangement is associated with a pole slot set containing at least two slots. Slots containing the coil legs of a first parallel path are positioned to the left of slots containing the coil legs of a second parallel path for a first group of pole slot sets. At least two of the coil connections intersect such that slots containing the coil legs of the first parallel path are positioned to the right of slots containing the coil legs of the second parallel path for a second group of pole slot sets.

[0006] In at least one further embodiment, a stator for an electric machine comprises a core including a plurality of slots and a multiphase winding arrangement positioned on the core, wherein each phase of the winding arrangement comprises a plurality of parallel paths extending through a plurality of pole slot sets. Each parallel path consists of a plurality of diamond- or rhomboid-shaped coils arranged around the core, with coil legs positioned in layers within the slots. Each phase of the winding arrangement defines a plurality of poles, and each pole is associated with a pole slot set containing a left slot, a middle slot, and a right slot.For each pole slot set, coil legs of a first parallel path are positioned in a first half of the layers of the left slot, coil legs of a second parallel path are positioned in the first half of the layers of the middle slot, coil legs for a third slot set are positioned in a second half of the layers of the middle slot, and coil legs for a fourth slot set are positioned in the second half of the layers of the left slot.

[0007] The features and advantages described above, as well as others, will be more readily apparent to those skilled in the field by reference to the following detailed description and the accompanying drawings. While it would be desirable to provide an electrical machine that incorporates one or more of these or other advantageous features, it may be obvious to those reviewing this disclosure that the teachings disclosed herein extend to those embodiments that fall within the scope of the accompanying claims, irrespective of whether they incorporate or realize one or more of the advantages or features mentioned herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The patent or application file contains at least one drawing in color. Copies of this patent or patent application publication with color drawing(s) are provided by the Office upon request and payment of the required fee. Fig. Figure 1 is a perspective view of a leading end of a stator including a diamond or rhombus coil winding arrangement. Fig. Figure 2 shows a perspective view of the opposite end of the stator of the Fig. 1. Fig. Figure 3 is a perspective view of the stator core of the Fig. 1 in isolation from the winding arrangement. Fig. Figure 4 is a perspective view of a diamond- or rhombus-shaped coil of the winding arrangement of the Fig. 1, wherein the coil contains segments in the slot, end windings and coil leads. Fig. Figure 5 shows a schematic diagram of the diamond coil winding arrangement of the Fig. 1, where the diagram represents a phase of the winding arrangement with the position of different conductors in the layers of slots and connections between the conductors. Fig. Figure 6 shows a perspective view of one phase of the winding arrangement of the Fig. 1 in isolation from the stator core, with the inner conductors extending axially upwards from the slots. Fig. Figure 7 shows a perspective view of one half of a phase of the winding arrangement of the Fig. 6 in isolation from the stator core. Fig. Figure 8 shows a perspective view of an alternative embodiment of one phase of the winding arrangement of the Fig. 1 in isolation from the stator core, wherein the inner conductors follow the angle of the coils (i.e., instead of extending axially upwards from the slots, as in the embodiment of the Fig. 6 and Fig. 7). Fig. 9A is a perspective view of the coil conductors before the diamond or rhombus coils were manufactured. Fig. 9B is a perspective view of the coil conductors of the Fig. 9A illustrating an embodiment of a method for forming the diamond or rhombus coils for the winding arrangement of the Fig. 1. DESCRIPTION

[0009] Herein lies a stator for an electrical machine. With general reference to the Fig. 1 and Fig. Figure 2 shows opposite sides of the stator 10. The stator 10 contains a stator core 12 with a multiphase winding arrangement 20 positioned on the stator core 12. Each phase of the winding arrangement 20 contains a plurality of parallel paths (which may also be referred to here simply as "parallel paths") that define a plurality of poles for the electric machine. Each parallel path contains a plurality of coils 30 positioned on the core, and each coil is defined by coil conductors in the slot 32, end windings 40 extending between the conductors in the slot 32, and coil leads 50. Coil terminals or connections 60 provide serial connections between the coils at a first end 26 of the stator core 12. As described in further detail herein, each pole in each phase of the winding arrangement is defined by a pole slot set consisting of several slots on the stator core.For each pole slot set, all parallel paths of the corresponding or associated phase of the winding arrangement are maintained or secured in the slots of the pole slot set. Stator core

[0010] Fig. Figure 3 shows a view of the stator core 12 isolated from the winding assembly 20. The stator core 12 is made of ferromagnetic material and is typically formed from a multitude of steel laminations that are stamped and stacked on top of each other to form a laminated core or stack. The stator core 12 is generally cylindrical in shape, as defined by a central axis 18, and includes an inner circumferential surface and an outer circumferential surface. The inner circumferential surface defines an inner diameter (ID) for the stator. The outer circumferential surface defines an outer diameter (OD) for the stator.

[0011] A plurality of teeth 14 are formed on the interior of the stator core 12 and directed inwards towards the central axis 18. Each tooth 14 extends radially inwards and terminates at the inner circumferential surface. Axial slots 16 are formed in the stator core 12 between the teeth 14. Each slot 16 is defined between two adjacent teeth, such that two adjacent teeth form two opposing radial walls for a slot. The teeth 14 and the slots 16 all extend from a first end 26 to a second end 28 of the core.

[0012] The slots 16 can be open or partially closed along the inner circumferential surface of the stator core 12. When the slots 16 are partially closed, each slot 16 has a width that is smaller on the inner circumferential surface than at more radially outward-facing positions (i.e., slot positions closer to the outer circumferential surface). When the slots are open, conductors can be inserted into the slots from the inner circumferential surface. In addition to the openings to the slots 16 through the inner circumferential surface (i.e., for open and partially closed slots), axial openings to the slots are also provided at the opposite ends 26, 28 of the stator core 12.

[0013] As it is in Fig. As shown in Figure 1, the stator core 12 is configured to retain or secure the winding assembly 20 within the slots 16 of the stator core 12. The winding assembly 20 is formed from a plurality of interconnected coils that are held or secured within the slots 16. The coils consist of several segments of copper or other electrically conductive material forming loops. The loops generally extend through the slots and wind around the teeth of the core. Coils of the winding arrangement

[0014] Now, if we refer to Fig. Figure 4 shows one of the coils 30 of the winding arrangement 20 in isolation from the winding arrangement. As shown in Fig. As shown in Figure 4, each coil is a diamond- or rhombus-shaped coil containing a plurality of straight conductors in slot 32, a plurality of end windings 40, and a plurality of coil leads 50. The straight conductors in slot 32 (which may also be referred to herein as "segments in slot" or "legs") extend through slots 16 from one end of the core 12 to the opposite end of the core. Two groups 32a and 32b of the segments in slot 32 are associated with each coil 30. Each group 32a, 32b of the segments in slot 32 extends through a different slot of the core. Each group 32a, 32b contains multiple segments in slot. In the embodiment of the Fig. 4 Each group 32a, 32b contains four segments in slot 32. These four segments in the slot are arranged one behind the other within slots 16 (i.e., in “layers” of conductors within the slot). Each slot is configured to retain or secure any number of segments in the slot in layers of the slot. In at least one embodiment, the slots 16 are configured to secure twice the number of segments in slot 32 as the number of conductors in each group 32a, 32b (e.g., each group 32a, 32b contains four conductors in slot 32, and each slot is configured with a total of eight layers of conductors in the slot).

[0015] In addition to the segments in slot 32, each coil 30 further contains end windings 40 and coil leads 50. The end windings 40 and coil leads 50 are provided as part of winding heads 36 and 38 of the winding arrangement 20 and are therefore arranged axially beyond the respective ends 26, 28 of the stator core 12. As shown in Fig. As shown in Figure 4, the end turns 40 (which may also be referred to herein as "end loops") extend between the two groups 32a, 32b of segments in the slot. In other words, each end turn 40 provides a bridge from the end of a conductor in one group 32a to the end of a conductor in another group 32b. Each end turn 40 contains a first angled sub-section 42 (which may also be referred to herein as "first segment") and a second angled sub-section 44 (which may also be referred to herein as "second segment"). The first sub-section 42 extends along a first end turn direction that is angled relative to the axial direction (i.e., relative to the central axis 18). Likewise, the second sub-section 44 extends along a second end turn direction that is angled relative to the axial direction. The two segments 42, 44 meet at a vertex 46 of the final turn.The vertex 46 defines the section of the end winding where the coil 30 changes direction while looping around the core (e.g., changing from a direction moving axially away from the core back to a direction moving axially towards the core). The angled sections 42, 44 of the coil 30 and their corresponding vertices result in a coil with a rhomboid shape.

[0016] Similar to the segments in slot 32, the end windings 40 also consist of conductive material, such as copper. As explained below in connection with the Fig. 9A and Fig. As discussed in further detail in Section 9B, the end windings 40 can be formed by providing conductor loops (i.e., “racetracks”) which are subsequently spread apart to form the desired conductor shape. Alternatively, in at least some embodiments, the segments in the slot 32 can be provided by I-pin conductors, and the end windings 40 and coil leads 50 can be printed at the ends of the segments in the slot 32 after the I-pin conductors have been inserted into the slots 16 of the core 12. An example of such a winding is disclosed in concurrently pending US patent application No. 63 / 173,241, the entire contents of which are incorporated herein by reference.

[0017] With continued reference to Fig. 4 Each coil 30 contains two coil leads 50. Each coil lead 50 provides a path into or out of the loop segments of each coil 30. In other words, when the coil former is viewed as containing the segments in the slot 32 and the end windings 40 forming loops, the coil leads 50 provide a path leading to the coil former. Fig. Figure 4 shows a first coil line 50y, which can be considered a “straight” coil line, since it extends directly from the segments in the slot 32 only in the axial direction and is not angled like the segments 42, 44 of the end winding 40. Fig. Figure 4 also shows a second coil lead 50z, which can be considered "bent" or "angled" because a portion of the coil lead 50z follows the angle of the end turn 40 before extending away from the coil body in the axial direction near the apex 46 of the end turn 40. While in Fig. Figure 3 shows both a straight coil lead 50y and a bent coil lead 50z. In at least one embodiment, both coil leads 50 are bent coil leads (i.e., both coil leads follow the angle of the end winding, similar to the second coil lead 50z), or both coil leads are straight coil leads 50y. As described in further detail herein, if both coil leads 50 are bent coil leads, the winding arrangement is better configured for radial insertion of the coils 30 into the slots 16 over the ID of the core 12.

[0018] As will be evident from the above, the coil of the Fig. 4. A diamond-shaped coil 30 containing a strand of wire wound in a loop to form a set of left legs 32a, a set of right legs 32b, first end turns 40a, and second end turns 40b. The four left legs 32a are all stretched in an axial direction and parallel to each other. Likewise, the four right legs 32b are all stretched in an axial direction and parallel to each other (and also parallel to the left legs 32a). The first end turns 40a connect the right legs to the left legs at one end of the coil 30, and the second end turns 40b connect the right legs to the left legs at the opposite end of the coil 30. The legs are all connected in series to form a coil, allowing current to flow from a first lead 50a at one end of the coil through all of the legs and to a second lead 50b at the same end of the coil 30. Complete winding arrangement

[0019] The plurality of coils 30 are interconnected to form the winding arrangement 20. For this purpose, the winding head 36 at the first end 26 of the core 12 contains different head segments, including the end winding segments 40 and coil leads 50 discussed above, as well as a plurality of connecting segments 60 that provide connections between the coils. As shown in Fig. As shown in Figure 1, each connecting segment 60 extends between the coil leads 50 of two different coils. In the embodiment disclosed herein, the connecting segments 60 extend circumferentially between the coils at a position that is radially outward from the end windings 40. Similar to the coils 30, the connecting segments are also made of copper or another electrically conductive material typical for winding arrangements in electrical machines.

[0020] Together, the coils 30 and the connection segments 60 form a winding arrangement 20 with a plurality of phase windings. In at least one embodiment, the winding arrangement comprises three phase windings (e.g., phase-U windings, phase-V windings, and phase-W windings) with multiple paths for each phase. Depending on the desired winding configuration, the three phase windings can be connected in a star ("Y") or delta ("Δ") connection.

[0021] A multitude of path conductors 70 are provided at the first end of the stator core together with the end windings 40 and coil connections or terminals 60. The conductors 70 define the entry and exit conductors for each parallel path of the stator. Because the stator is a three-phase machine and because there are four parallel paths per phase, in this embodiment the Fig. Figure 1 shows a set of twelve conductors (i.e., 70a to 701) in the outer layers of the winding. Twelve additional conductors are provided in more inwardly directed layers of the winding. The conductors for each phase are connected in parallel (i.e., each phase contains four parallel paths). The plurality of path conductors 70 is, as a whole, suitably positioned so that they generally extend from a single quadrant of the stator 10. In other words, as shown in Figure 1, the conductors are arranged in a single quadrant of the stator 10. Fig. As shown in Figure 1, the path leads 70a to 70l are all arranged within an arc of approximately 90° (e.g., an arc of less than 100° and preferably 90° or less) on the stator core. The end windings 40, coil leads 50, coil connections 60, and path leads 70 form a first winding head 36 at one end 26 of the stator core.

[0022] Fig. Figure 2 shows a second winding head 38, which is provided at the opposite end of the stator core from the first winding head 36. As shown in Fig. As can be seen in Figure 2, the winding head 38 contains only end windings 40 and does not contain the coil leads 50, the connecting segments 60, or the leads 70. Together, the Fig. 1 and Fig. 2 the opposite ends 26, 28 of the stator 10 with the winding heads 36, 38 of the winding arrangement 20 on the stator core 12. The segments in the slot 32 of the coils 30 extend through the slots 16+ between the respective winding heads 36 and 38.

[0023] Now, if we refer to Fig. Figure 5 shows a schematic / tabular view of the winding arrangement 20 with the legs of the diamond-shaped coils arranged in the slots of the stator core. As shown in Fig. As shown in Figure 5, forty-eight slots (i.e., slot #1 to slot #48) are contained in the core, and each slot contains eight layers of conductors (i.e., eight segments extend into slot 32, arranged one after the other in each slot, axially through each slot). As shown on the left side of the Fig. As indicated in 5, these eight layers contain "Layer 1" (near the kernel's ID) to "Layer 8" (closer to the kernel's OD). For simplicity, in Fig. Figure 5 shows only one phase of conductors and the core and associated stator slots are shown in a linear manner (i.e. not in the actual annular shape).

[0024] Each phase of the winding arrangement 20 contains parallel paths of conductors that form coils 30, as they loop around the slots 16 and the path winds around the core 12. Each color in Fig. 5 represents the conductor for one of the four parallel paths for a phase of the winding arrangement. Specifically, these four parallel paths are in Fig. 5 is represented as blue path 52, green path 54, yellow path 56, and orange path 58. The number symbols 1-8 are superimposed on each of the colors of each path 52, 54, 56, 58. The odd number symbols (i.e., 1, 3, 5, 7) within the color represent conductors in the slot associated with a right leg of a diamond-shaped coil 30, and the even number symbols within the color (i.e., 2, 4, 6, 8) represent conductors in the slot associated with a left leg of the same diamond-shaped coil. The double arrows 51, extending between pairs of conductors in the slot of the same color, represent the end-turn connections or terminals between the left and right legs of a coil (e.g., a green double-sided arrow represents a connection between the left and right legs of the green path 54, etc.).For example, the double-sided arrows 51a within a circle 53 show that the coils for the blue path 52 and the green path 54 extend between slots 34 and 39 and slots 33 and 38, respectively. Similarly, the double-sided arrows 51b from circle 57 show that the coils for the yellow path 56 and the orange path 58 extend between slot 27 and slot 32, and between slot 28 and slot 33, respectively. It is derived from... Fig. It can be seen from Figure 5 that all of the coils 30 have a pitch of five (i.e., the left legs of each coil are separated from the right legs by five slots). The coils 30 are also interleaved on the core 12 with left legs (i.e., segments in slot 32) of each coil positioned in the outer half of the slot layers (i.e., layers 5-8), and right legs of the same coil positioned in the inner half of the slot layers (i.e., layers 1-4).

[0025] With continued reference to Fig. 5 can be seen that each phase of the winding arrangement 20 defines eight poles 80 (which are indicated by the slot numbers in Fig. 5 are designated 1-8). Additionally, each pole 80 within a phase of the winding arrangement 20 is connected to a pole slot set 86. In the embodiment of the Fig. Each pole slot set contains three slots, and each slot accommodates eight layers of conductors. Each pole slot set 86 also defines a 4-8-4 conductor arrangement such that four conductors of a first parallel path are arranged in inner layers of the left slot, four conductors of a second parallel path are arranged in inner layers of the middle slot, four conductors of a third parallel path are arranged in outer layers of the middle slot, and four conductors of a fourth parallel path are arranged in outer layers of the right slot. For each pole slot set 86, all parallel paths of the associated phase shift pass through one of the slots of the pole slot set. For example, pole #7 is defined by pole slot set 86a, which contains slots #s 8, 9, and 10. In this pole slot set 86a, the green path 54 is in the inner layers of the left slot (i.e.,The blue path 52 is maintained or secured in the inner layers of the middle slot (i.e., layers 1-4 of slot #10), the yellow path 56 is maintained or secured in the outer layers of the middle slot (i.e., layers 5-8 of slot #9), and the orange path 58 is maintained or secured in the outer layers of the right slot (i.e., layers 5-8 of slot #8).

[0026] From the Fig. 5 It will be seen that the positions of the different paths traverse different slots of the pole slot sets and different layers of each slot. For example, the blue path 52 (i) is maintained in the inner layers of the left slot in the pole slot sets for poles #1 and #3, (ii) is maintained in the outer layers of the middle slot in the pole slot sets for poles #2 and #8, (iii) is maintained in the outer layers of the right slot in the pole slot sets for poles #4 and #6, and (iv) is maintained in the inner layers of the middle slot in the pole slot sets for poles #5 and #7. Each of the other paths 54, 56, and 58 also traverses the different pole slot sets in a similar manner (i.e.,(moving in the left, middle, and right slots of different pole slot sets and in different layers of the slots). As a result, a winding arrangement 20 is formed in which, for each pole slot set 86, legs 32 extend through a slot of the pole slot set 86 for each parallel path 52, 54, 56, 58, such that conductors for all of the parallel paths 52, 54, 56, 58 of this phase of the winding arrangement are maintained or secured in each pole slot set 86. While . Fig. Figure 5 shows the parallel paths 52, 54, 56, 58 through the pole slot sets 86 specifically for one phase of the winding arrangement; the pole slot sets for two additional phases of the winding arrangement are shown in Fig. 5 is also represented by the gray and white shading. Additionally, the term “adjacent pole slot sets,” as used herein, refers to two pole slot sets that are associated with or connected to successive / adjacent poles. For example, successive poles #5 and #6 define in Fig. 5 adjacent pole slot sets (i.e., the pole slot sets 86 appear in conjunction with pole #5 and pole #6).

[0027] Fig. Figure 5 also represents the coil connections 60, which provide series connections or circuits between the coils 30 of the winding arrangement 20 (and may also be referred to herein as "series connections"). In the embodiments disclosed herein, these coil connections 60 are arranged radially outwards from the end windings 40 (see Figure 5). Fig. 1) and are in Fig. 5 represented by red arrows 61. Each red arrow 61 represents a coil connection that links two different coils via a series connection between coil leads extending from layer #4 of one pole and coil leads extending from layer #8 of another pole. In other words, the red arrows 61 represent coil connections that link a first coil lead of a first coil (which first coil lead extends from a right leg of the first coil, positioned in an inner layer of a slot) to a second coil lead of a second coil (which second coil lead extends from a left leg of the second coil, positioned in an outer layer of another slot).

[0028] The red arrows 61 in Fig. Figure 5 contains both solid-line arrows 61a and dashed-line arrows 61b. The solid-line arrows 61a represent coil connections that do not cross each other and do not change the position of the path relative to an adjacent path (i.e., two paths are adjacent if the coils of the paths extend through adjacent slots within the pole slot sets). For example, the solid-line arrows 61a that run between pole #6 and pole #5 in Fig. 5 extend, the position of the green path 54 relative to the blue path 52 does not (i.e., the green path 54 is to the left of the blue path 52 in both of the adjacent pole slot sets for pole #5 and pole #6). The coil connections, indicated by the solid line arrows 61a of the Fig. The 5 connected or associated coils all have a pitch of seven. On the other hand, the arrows with dashed lines 61b represent the coil connections 60, which intersect (i.e., cross over / around each other in a radial and / or axial direction), thus causing the associated adjacent parallel paths to also intersect, so that the relative coil positions of the two parallel paths within the adjacent pole slot sets are reversed. For example, the arrows with dashed lines 61b, which run between pole #8 and pole #7 in Fig. 5 extend, coil connections 60 represent, which cross and change the position of the coils for the green path 54 relative to the blue path 52 (i.e., the green path 54 is to the left of the blue path 52 in the pole slot set of pole #7, but is to the right of the blue path 52 in the pole slot set for pole #8). The coil connections, indicated by the arrows with dashed line 61b of the Fig. 5 are associated, all have pitches of six or eight (i.e., each coil connection pair associated with adjacent coils has respective pitches of six and eight).

[0029] In addition to all the foregoing, it will also be recognized that Fig. Figure 5 further shows the position of the leads for the winding arrangement 20. The leads are in Fig. 5 are represented by black boxes around the associated conductors. The conductors include conductors of an outer layer 70 (i.e., conductors in layer 8) as well as conductors of an inward-facing layer 72 (i.e., conductors in layer 4). For the winding arrangement 20, an entirety of eight distinct conductors is shown, including the four black boxes around the “1” conductors in layer 4 of poles #2 and #3 and the four black boxes around the “8” conductors in layer 8 of poles #3 and #4. It will be recognized that each of the conductors 70, 72, which are represented by black boxes in Fig. Lines 5 shown are either phase lines or neutral lines. Lines 70 and 72, which extend from poles 2 and 4 in Fig. The lines extending from pole 5 are of the same type (i.e., both are neutral lines or both are phase lines). Lines 70 and 72, extending from pole 3, are also of the same type but are different from the lines extending from poles 2 and 4 (i.e., either phase lines or neutral lines, which are also different from those at poles 2 and 4). Connected coils of a complete winding arrangement

[0030] Fig. Figure 6 shows a perspective view of coils 30, which are connected to a phase of the winding arrangement of the Fig. 5 are associated. The coils 30 are shown in isolation from the core 12 to illustrate the positions and connections between the coils. As shown in Fig. As shown in Figure 6, the coils are provided in each of four parallel paths, including a blue path 52, a green path 54, a yellow path 56, and an orange path 58. The coil connections 60 extend circumferentially between adjacent coils along the outer diameter (OD). The coil connections or terminals 60 connect to the coil leads 50 and connect adjacent coils in series. Figure 6 again shows... Fig. 6 a phase of the winding arrangement 20 in which all diamond or rhombus coils of one color are connected together in series.

[0031] Fig. Figure 7 shows a perspective view of one half of a phase (i.e., blue path 52 and green path 54) of the ladder. Fig. 6. Fig. Figure 7 is intended to show the relationship between sets of adjacent coils 30a, 30b more clearly by showing the adjacent coils in isolation from other coils of the winding arrangement 20. Series coil connections 60 with the crossed arrangement (shown above in conjunction with Fig. (as described in section 5) can also be found at arrow 62 in Fig. 7 can be seen. As it is in Fig. As shown in Figure 7, the coil leads 50, and in particular the inner coil leads, are straight coil leads 50a extending axially out of a slot before rotating radially outward and then circumferentially toward an adjacent coil. As a result, adjacent coils of the winding arrangement are interlocked. As shown in Fig. As shown in Figure 7, each coil 30a is interlocked with the corresponding adjacent coil 30b within the winding arrangement 20, such that no coil can be removed from the winding arrangement in a radial direction without removing the corresponding adjacent coil. This interlocking relationship is shown in particular by the circles 81 and 82 in Figure 7. Fig. Figure 7 shows that, as shown by circle 81, the first segment 42a of the end winding of coil 30a is arranged radially inward from the coil lead 50b of the corresponding adjacent coil 30b. At the same time, as shown by circle 82, the second segment 44a of the end winding of coil 30a is arranged radially outward from the first segment 42b of the end winding of the corresponding adjacent coil 30b. As a result, coil 30a is interlocked with the adjacent coil 30b, since the second segment 44a of coil 30a is wedged (i.e., enclosed) in the radial direction between the coil lead 50b and the second segment 44b of the adjacent coil.

[0032] Fig. Figure 8 shows a perspective view of an alternative embodiment of the coils from one phase of the winding arrangement 20. In this embodiment, the inner coil leads are not straight coil leads. Instead, the inner coil leads are all angled coil leads 50 (i.e., a bent lead 50z, as shown in Figure 8). Fig. (as shown in Figure 4), which follow the angle of the coil end windings 40, which is opposite to extending directly upwards (i.e., axially) out of a slot. The angle of these coil leads 50 is helpful in allowing the winding to be inserted radially from the inner diameter (ID) of the stator core. Since the coil leads 50 are curved coil leads, they are positioned directly adjacent to the vertex / corner point 46 of the end winding for the same coil 30. Method for manufacturing coils for a winding arrangement

[0033] Fig. 9A and Fig. 9B represents a method for producing the rhombus-shaped or diamond-shaped coils 30, which are used in the winding arrangement 20 of the Fig. 8 can be used. As it is in Fig. As shown in Figure 9A, relatively narrow coil loops 90 are wound first. Since the parallel sides 92 of these loops 90 are relatively close together, the loops 90 can also be referred to as "racetrack" coils. Each racetrack coil 90 contains end windings 94 and two coil leads 96. It will be noted that in Fig. 9A Two identical coils 90 are shown to illustrate that the described process is repeated for each coil 30 of the winding arrangement 20.

[0034] As it is in Fig. As shown in Figure 9B, in order to form the coils 30 for the winding arrangement described herein, the opposing elongated sides 92 of the racetrack loops 90 are spread apart, as indicated by double arrows 98, to form the coils 30 with end windings 40 that provide the correct pitch between the sets of legs on the left and right sides of the coil. This spreading apart of the sides 92 is carried out perpendicular to the axial direction of the sides 92. In at least one embodiment, the spreading is carried out by securing the opposing end windings 94 of the loops 90 and applying opposing forces to the upper and lower portions of the parallel sides of the loops 90, as indicated by double arrows 98. In at least one embodiment, in which all coils are already connected (i.e.,(When using a continuous length of wire to form multiple coils), it is generally desirable to align all coils in a linear line or circle before spreading the sides. This allows the coils to nest together more effectively.

[0035] In light of all the foregoing, it will be recognized that a stator with diamond or rhombus coils and several parallel paths with a balanced winding arrangement is disclosed herein. The stator generally incorporates one or more of the following features in different embodiments of the stator: - Diamond coils, wherein the coils are continuously formed with a single wire or individual welded diamond coils (see Fig. 6 and Fig. 7); - Multiple slots per pole per phase (in Fig. 5 are two shown); - Multiple parallel paths per phase (in Fig. 5 are four shown, including the blue path 52, the green path 54, the yellow path 56 and the orange path 58); - Each diamond coil has a short pitch (in Fig. 5 is a pitch of 5 for a normal stator with six pitches shown); - Each pole has a set of parallel wires in inner layers of a left slot (i.e. layers 1-4), another set of parallel wires in inner layers of a middle slot (i.e. layers 1-4), a third set of parallel wires in outer layers of the middle slot (i.e. layers 5-8) and a fourth parallel wire in inner layers of a right slot (i.e. layers 5-8); - Each diamond coil has right and left legs, with either the right or left legs in a middle slot and the opposite legs (i.e., left or right) in a left or right slot (i.e., if the right legs are in the middle slot, then the left legs are in the left slot, and if the right legs are in the right slot, then the left legs are in the middle slot); - Halfway through the winding, two of the parallel wires will cross, causing the wires to change positions in the three slots in the next half of the winding.

[0036] The winding arrangement 20 with diamond-shaped coils, as disclosed herein, has numerous advantages. For example, as discussed above, the phase leads / phase conductors all protrude from (or nearly from) a single quadrant. Likewise, each parallel wire is accommodated in all poles; that is, each pole slot set contains all the parallel wires. This provides improved electrical balancing of the parallel conductor paths of the winding arrangement in the event that the rotor / stator combination is not exactly concentric (e.g., as a result of manufacturing tolerances).

[0037] While embodiments of the winding arrangement are disclosed herein, it will be recognized that other embodiments are possible. For example, unlike the arrangement of the Fig.5, in at least one embodiment, each pole of the winding arrangement has a set of parallel wires in inner layers of a right slot (i.e., layers 1-4), another set of parallel wires in inner layers of a middle slot (i.e., layers 1-4), a third set of parallel wires in outer layers of the middle slot (i.e., layers 5-8), and a fourth parallel wire in inner layers of a left slot (i.e., layers 5-8). Accordingly, when a slot set having three contiguous slots, including a left slot, a middle slot, and a right slot, is described herein, it will be recognized that the terms left, middle, and right can be determined based on a perspective of either the ID or the OD.

[0038] Although the various embodiments have been provided herein, it will be understood by those skilled in the field that other implementations and adaptations are possible. Furthermore, aspects of the various embodiments described herein can be combined or replaced with aspects from other features to arrive at embodiments other than those described herein. It will thus be understood that various features and functions disclosed above, as well as other features and functions or alternatives thereof, can be desirablely combined in many other different systems or applications. Various currently unforeseen or unexpected alternatives, modifications, variations, or improvements thereto, which may also be encompassed by any claims that may be appended, may subsequently be made by those skilled in the field.

Claims

[1] Stator (10) for an electric machine, comprising: a core (12) containing a plurality of slots (32, 16); and a multiphase winding arrangement (20) positioned on the core (12), wherein each phase of the winding arrangement (20) comprises a plurality of parallel paths (52, 54, 56, 58) defining a plurality of poles (80), wherein each parallel path (52, 54, 56, 58) contains a plurality of coils (30) positioned on the core (12), each coil (30) being defined by coil legs and end windings (40), the coil legs comprising left legs (32a) and right legs (32b) extending through the slots (32, 16) of the core (12), and the left legs (32a) and right legs (32b) of each coil (30) being connected by first end windings (40a) at one end of the core (12) and second end windings (40b) at an opposite end of the core (12), wherein each pole (80) is associated with a pole slot set (86) consisting of several slots (32, 16), wherein each pole slot set (86) contains a left slot, a middle slot and a right slot, wherein for each pole slot set (86) legs for each parallel path (52, 54, 56, 58) extend through a slot (32, 16) of the pole slot set (86) such that conductors for all of the parallel paths (52, 54, 56, 58) of the phase of the winding arrangement (20) are maintained or secured in each pole slot set (86), wherein for each pole slot set (86) left legs (32a) of a first coil (30) are in an outer half of the middle slot and right legs (32b) of the first coil (30) are in an inner half of a left slot of a right adjacent pole slot set (80), wherein each of the multiple coils (30) are diamond- or rhomboid-shaped coils, wherein each parallel path (52, 54, 56, 58) further contains series connections (61) extending between sets of the plurality of coils (30), wherein each set of coils (30) comprises at least two adjacent coils (30), wherein the series connections (61) are positioned radially outwards from the first terminal windings (40a) at one end of the core (12), characterized by , that at least two of the series connections (61b) extending between two sets of the plurality of coils (30) run in such a crisscrossing manner that a coil position associated with each series connection (61) switches slot positions in an adjacent pole slot set (80), wherein the at least two intersecting series connections (61b) comprise a first series connection which intersects a second series connection, the first series connection extending between at least two adjacent coils (30) by two slot positions further than the second series connection, and wherein the first row connection extends one slot position further than the other row connections of the associated parallel path (52, 54, 56, 58). [2] Stator according to claim 1, wherein the multiphase winding arrangement (20) is a three-phase winding arrangement. [3] Stator according to claim 1, wherein the winding arrangement (20) further comprises a first conductor and a second conductor for each parallel path (52, 54, 56, 58), wherein all of the conductors are arranged within an arc of 100° defined at the core (12). [4] Stator according to claim 3, wherein all of the conductors are arranged within an arc of 90° defined at the core (12). [5] Stator according to claim 1, wherein the plurality of parallel paths (52, 54, 56, 58) is defined by four parallel paths for each phase of the winding arrangement (20). [6] Stator according to claim 5, wherein the number of slots (32, 16) per phase per pole (80) of the winding arrangement (20) is two. [7] Stator according to claim 6, wherein each pole slot set (86) contains three connected slots (32, 16) defining a left slot, a middle slot and a right slot. [8] Stator according to claim 7, wherein eight layers of conductors are arranged in each slot (32, 16) and wherein each pole slot set (86) defines a 4-8-4 conductor arrangement such that four conductors of a first parallel path (52, 54, 56, 58) are arranged in inner layers of the left slot, four conductors of a second parallel path (54, 56, 58, 52) are arranged in inner layers of the middle slot, four conductors of a third parallel path (56, 58, 52, 54) are arranged in outer layers of the middle slot and four conductors of a fourth parallel path (58, 52, 54, 56) are arranged in outer layers of the right slot. [9] Stator according to claim 1, wherein for each pole slot set (86) the left legs of a second coil are in an outer half of the right slot and the right legs of the second coil are in the middle slot of the right adjacent pole slot set (86). [10] Stator according to claim 9, wherein for each pole slot set (86) the right legs of a third coil are in an inner half of the middle slot and the left legs of the third coil are in the right slot of a left adjacent pole slot set (86). [11] Stator according to claim 1, wherein for each pole slot set (86) the right legs of a fourth coil are in an inner half of the left slot and the left legs of the fourth coil are in an outer half of the middle slot of the left adjacent pole slot set (86).

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