Axial Flux Stator Teeth With Radial Split Windings
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Solution Overview
Problem
Existing stators for axial flux machines face challenges in maximizing electric loading due to limitations in the available circumferential length for windings and insulation, which restricts the cross-sectional area and leads to inefficient flux conduction.
Innovation Solution
The stator design splits each stator tooth radially into multiple part teeth, allowing for a varying number of winding turns on each part tooth. This configuration optimizes the winding cross-section in radially outer areas without compromising the flux-conducting elements in inner areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the winding and insulation have a constant cross-section along the winding around the flux-conducting element, then the manufacturing is simplified, but the available circumferential length is insufficient in radially inner areas, limiting the flux-conducting element width
Solution Approach 1:
The stator tooth is divided into multiple radially arranged part teeth (first, second, third part teeth), allowing different winding configurations in different radial zones. This segmentation enables the flux-conducting elements in radially inner areas to maintain sufficient width while allowing larger winding cross-sections in radially outer areas where more circumferential length is available.
Solution Approach 2:
Different parts of the stator tooth are assigned different functions and dimensions. The radially inner part teeth have larger flux-conducting element widths to ensure adequate magnetic flux conduction, while the radially outer part teeth accommodate larger winding cross-sections where more space is available. This local differentiation optimizes both magnetic performance and electrical loading.
2Reliability
If the circumferential widths of winding and insulation are limited to maintain minimum flux-conducting element width, then the flux conduction is preserved, but the electric loading capacity of the stator is reduced
Solution Approach 1:
By segmenting the stator tooth radially into multiple part teeth, the invention creates distinct zones for flux conduction and winding placement. The inner part teeth prioritize flux conduction with adequate element width, while outer part teeth maximize winding cross-section area, thereby increasing overall electric loading capacity without compromising flux conduction reliability.
Solution Approach 2:
The invention transitions from a two-dimensional constant cross-section winding approach to a three-dimensional variable cross-section approach by utilizing the radial dimension. Winding cross-sections vary along the radial direction, with larger cross-sections in outer regions and smaller cross-sections in inner regions, maximizing the use of available space while maintaining flux conduction integrity.
3Quantity of substance
If more winding cross-section is placed in radially outer areas, then the electric loading is increased, but the available circumferential length for flux-conducting elements in radially inner areas becomes insufficient
Solution Approach 1:
The stator tooth is segmented into multiple radially arranged part teeth, creating distinct functional zones. This segmentation allows the radial distribution of winding cross-sections to be optimized independently in each zone, placing maximum winding area in outer regions where space permits while preserving adequate flux-conducting element widths in inner regions.
Solution Approach 2:
Each radially positioned part tooth is designed with local quality appropriate to its position: inner part teeth have larger flux-conducting element widths relative to their size, while outer part teeth accommodate proportionally larger winding cross-sections. This local optimization resolves the conflict between electric loading and flux conduction requirements.
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 design enhances the electric loading capacity of the stator by allowing a more efficient distribution of winding cross-section and flux-conducting material across different diameters, thereby improving the overall performance of the axial flux machine.
Implementation Method 1
stator windings (3), which are arranged around the stator teeth (11) and are each wound around a stator tooth (11) as a single-tooth winding
Data Source
AI summary
A stator for an electric axial flux machine, more particularly a stator for an axial flux machine designed as a prime mover for an electrically driven motor vehicle, which stator includes a stator body with a plurality of stator teeth distributed around the circumference and stator windings. At least one of the wound stator teeth is split, seen in the radial direction, into at least two stator part teeth, wherein the at least two stator part teeth are wound with a different number of turns of the stator winding.