Claw-pole Rotor Winding Design for Slot Fill and Noise
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Solution Overview
Problem
Existing electrical machines with claw-pole rotors face challenges in maximizing slot area and reducing slot spread while maintaining low production costs and minimizing noise and insulation damage.
Innovation Solution
A five-phase electrically excited claw-pole machine with a sixteen-pole rotor and a stator core made from pre-stamped sheet metal, featuring a distributed wave winding design that increases slot fill factor and reduces yoke height, thereby enhancing output power and noise reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a simple wave winding is used, then the winding can be produced at low cost, but the slot fill factor is low and the pull-in force is high
Solution Approach 1:
The patent changes the winding configuration from simple wave winding to distributed wave winding with multiple strands (5 strands), which modifies the winding parameters to achieve higher slot fill factor while maintaining low production cost through the pull-in winding method
2Strength
If the yoke height is increased, then the structural strength is improved, but the slot depth is reduced and slot area is reduced
Solution Approach 1:
The patent optimizes the yoke height parameter to achieve the best compromise between structural strength and slot area, using a specific yoke height range that allows sufficient mechanical strength while maximizing the available slot area for winding placement
3Ease of operation
If the slot spread is increased, then the winding insertion is facilitated, but the slot area is reduced and magnetic performance deteriorates
Solution Approach 1:
The patent optimizes the slot spread parameter within a specific range that balances the ease of winding insertion with the preservation of sufficient slot area, achieving both manufacturability and magnetic performance
4Device complexity
If conventional winding methods are used, then the production process is simple, but the winding insulation is at risk of damage
Solution Approach 1:
The patent employs a pull-in winding method where the winding is inserted into the slots in a controlled manner, with preliminary positioning and guiding structures that prevent insulation damage during the winding insertion process
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
The design increases slot area and output power, reduces noise, and simplifies winding insulation protection, achieving a high slot fill factor at low costs without risking insulation damage.
Implementation Method 1
an electrically excited claw-pole machine with a sixteen-pole rotor and a stator core made from pre-stamped sheet metal, featuring a distributed wave winding design
Data Source
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AI summary
The invention relates to an electric machine comprising a claw-pole rotor, particularly an electrically excited, at least 12-pole claw-pole machine (10) for a motor vehicle. The stator (16) of the machine, the winding of which has multiple phase windings and is connected to a rectifier arrangement (69) or alternatively to a pulse-controlled inverter arrangement using the phase winding connections (80 to 84) of said winding, has an inner diameter (Di) that is smaller than the associated outer diameter (Da) of the machine by a factor of 0.70 to 0.77, preferably by a factor of 0.73 to 0.75, at least in the groove center. According to the invention, the ratio of the groove widths (Bn2) at the groove openings (37) to the groove widths (Bn1) at the respective groove base (36) lies in the range of 0.69 to 0.81, preferably in the range of 0.73 to 0.78.