Balanced Wave Stator Windings With Variable Pitch Turns
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Solution Overview
Problem
Existing electric motor designs with 72 slots and 6 conductors per slot face challenges in achieving balanced stator windings, leading to inefficiencies and increased manufacturing costs due to the need for large busbar assemblies and numerous welds, particularly when all pitch turns are of the same length.
Innovation Solution
The design incorporates conductors wound in a wave pattern around the stator, forming three balanced parallel paths with varying pitch turns, including standard and nonstandard turns, which create a repeating pattern to achieve balanced flux distribution without the need for extensive busbar assemblies and welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If all pitch turns are of the same length (standard design), then the winding structure is simple, but the flux distribution becomes unbalanced leading to inefficiencies
Solution Approach 1:
The patent applies local quality by varying the pitch turn lengths in specific locations around the stator. Instead of using uniform pitch turns throughout, the design incorporates different pitch turn lengths (e.g., some turns spanning 12 slots, others spanning 13 or 11 slots) at specific positions to achieve balanced flux distribution in critical areas while maintaining simplicity elsewhere.
Solution Approach 2:
The patent changes the parameter of pitch turn length from a constant value to a variable value. By modifying the pitch turn length parameter in a controlled manner around the stator circumference, the design achieves balanced flux distribution without requiring complex winding structures or additional busbar assemblies.
2Loss of energy
If balanced flux distribution is achieved through conventional methods, then flux balance is improved, but manufacturing cost increases due to large busbar assemblies and numerous welds
Solution Approach 1:
The patent extracts and eliminates the need for large busbar assemblies and numerous welds from the conventional design. By achieving flux balance through varied pitch turns in the winding pattern itself, the design removes the requirement for extensive external busbar connections, thereby reducing device complexity and manufacturing cost.
Solution Approach 2:
The winding pattern itself performs the flux balancing function that would otherwise require separate busbar assemblies. The varied pitch turns create inherent flux balance within the winding structure, allowing the system to self-regulate flux distribution without additional components.
3Ease of manufacture
If conventional winding patterns are used, then manufacturing process is straightforward, but efficiency is reduced due to unbalanced flux distribution
Solution Approach 1:
The patent maintains winding process simplicity by applying local variations to the pitch turn pattern rather than requiring a complete redesign of the manufacturing process. The varied pitch turns are implemented through straightforward winding adjustments at specific locations, preserving ease of manufacture while improving flux balance and efficiency.
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 approach enhances efficiency, reduces manufacturing costs, and simplifies the stator winding process by maintaining balanced flux distribution across parallel paths, thereby improving the overall performance and cost-effectiveness of the electric motor.
Implementation Method 1
an electric motor comprises: a rotor having poles equaling a first number; and a stator having slots equaling a second number, the stator having stator windings formed by conductors wound in a wave pattern around the stator
Data Source
AI summary
An electric motor comprises: a rotor having poles equaling a first number; and a stator having slots equaling a second number, the stator having stator windings formed by conductors wound in a wave pattern around the stator, wherein a third number of the conductors are located in each of the slots, wherein the conductors form three balanced parallel paths through the slots, each of the conductors in the three balanced parallel paths undergoing a same number of pitch turns, each of the pitch turns being either a standard pitch turn or a nonstandard pitch turn, the standard pitch turn involving wrapping around slots equaling the second number divided by the first number, the nonstandard pitch turn involving wrapping around more or fewer slots than the standard pitch turn, wherein each of the three balanced parallel paths forms a repeating pattern throughout the slots.