Balanced Stator Windings Using Single Continuous Conductor
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Solution Overview
Problem
Existing electric motor stator winding methods face challenges in achieving balanced windings efficiently, particularly in compact spaces and during manufacturing, where prior-art methods often result in unbalanced or complex configurations.
Innovation Solution
A method for winding a multi-phase electric motor stator using a single continuous conductor to create balanced windings, where each tooth receives an equal number of turns, with the conductor looping around the stator axis and connectors positioned to simplify the lead frame design, allowing for balanced and efficient winding configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single continuous conductor is used to wind all teeth of a phase, then balanced windings are achieved with equal turns per tooth, but the winding process becomes more complex and time-consuming
Solution Approach 1:
The conductor is pre-configured with predetermined sections and connection points before the winding process begins. The connection points are positioned in advance to align with specific teeth, allowing the winding operation to proceed systematically without complex real-time adjustments, thus maintaining balance while improving efficiency
Solution Approach 2:
The single continuous conductor is divided into multiple predetermined sections, each section being assigned to wind a specific tooth. This segmentation allows parallel processing of different teeth while maintaining the overall balance requirement, resolving the contradiction between precision and productivity
2Productivity
If multiple separate conductors are used for different teeth, then manufacturing is simpler and faster, but balanced windings are difficult to achieve
Solution Approach 1:
The single continuous conductor serves multiple functions: it winds multiple teeth to achieve balanced windings, provides inherent electrical connection between teeth, and maintains consistent electrical properties throughout the phase. This multi-functionality allows simplified manufacturing processes while ensuring precision in the final winding configuration
Data Source
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AI summary
A stator for a multi-phase electric motor comprises a plurality of teeth (12), (14, 16) for each phase. The windings on two teeth (12a, 12b) from one phase are formed from a single length of conductor 18. The windings on a first one (12a) of the teeth being formed at least in part from two sections (18c, 18d) of the conductor spaced apart along the length of the conductor, and the windings on a second one (12b) of the teeth being formed from an intermediate section (18e) of the conductor between the spaced apart sections.