Chorded Stator Winding Layout for Lower Torque Ripple
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Solution Overview
Problem
Stators with unchorded winding zones in electric machines experience significant torque ripples, harmonics, noise, and vibrations, which affect the efficiency and reliability of vehicle-driven electric machines.
Innovation Solution
A stator design with a chorded winding configuration, where two layers of winding zones are offset in the circumferential direction, forming a combined lap and wave winding, reducing torque ripples and harmonics, and increasing the number of connector/conductor combinations for improved production friendliness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If unchorded winding zones are used in the stator, then the manufacturing process is simpler, but torque ripples, harmonics, noise, and vibrations increase significantly
Solution Approach 1:
The stator winding is divided into multiple discrete layers (first through sixth layers) with specific conductor arrangements in each layer. This segmentation allows precise control of the winding configuration to achieve chording while maintaining manufacturing feasibility through standardized layer structures.
Solution Approach 2:
The patent implements asymmetric offset positioning where the first and second layers are offset by one slot relative to the third and fourth layers in the circumferential direction. This asymmetric arrangement creates the chorded winding configuration that reduces torque ripples and harmonics while preserving ease of manufacture.
2Object-generated harmful factors
If chorded winding configuration with layer offsets is implemented, then torque ripples and harmonics are reduced, but the device complexity increases
Solution Approach 1:
By dividing the winding into six distinct layers with standardized conductor patterns, the complex chorded configuration is broken down into manageable segments that can be manufactured and assembled systematically, reducing the perceived complexity despite the advanced winding pattern.
Solution Approach 2:
Different layers have different offset configurations (first and second layers offset differently from third and fourth layers), creating local variations in winding quality that collectively achieve the overall chording effect while maintaining a regular overall structure.
3Object-generated harmful factors
If chorded stator design with layer offsets is used, then noise and vibrations are reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The offset configuration is applied in discrete one-slot increments between specific layer pairs, creating clearly defined positioning targets that simplify manufacturing precision requirements compared to continuous offset adjustments.
Solution Approach 2:
The patent combines the offset configuration of multiple layer pairs (first-second layers with third-fourth layers) to achieve the noise and vibration reduction effect, distributing the precision requirements across multiple standardized features rather than requiring high precision in a single feature.
4Productivity
If the number of connector/conductor combinations is increased for production friendliness, then automated manufacturing efficiency improves, but the device complexity increases
Solution Approach 1:
The stator winding is divided into six standardized layers with repeating conductor patterns, allowing automated manufacturing systems to use standardized connector configurations that can be efficiently replicated across multiple slots and phases.
Solution Approach 2:
The connector design accommodates multiple conductor combinations through a universal connector configuration that can handle different layer offsets and phase arrangements, increasing production flexibility without requiring multiple specialized connector types.
Data Source
AI summary
Stator for an electric machine has a number N of phases (U, V, W), a number P of pole pairs and a number of holes q, wherein N≥3 and P≥2 and q=3. The stator includes a stator core having a plurality of slots and a plurality of shaped conductors, which are arranged in the slots so as to be radially layered in a first to Lth layer, wherein L=6. The shaped conductors of each phase form a first path and second path, which can be or are interconnected in series or in parallel with each other and are arranged in P first winding zones and P second winding zones, wherein the first and second winding zones alternate in the circumferential direction. The shaped conductors of a respective path are interconnected to form a series connection by connectors.