Compact Stator Design for Rotating Electrical Machines
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Solution Overview
Problem
Conventional distributed winding stators for rotating electrical machines face challenges in compact connection and arrangement of wire terminals, flexibility during coil insertion, and space factor limitations, leading to increased size and reduced heat dissipation performance.
Innovation Solution
The design incorporates a stator with element coils of the same phase connected through a coil-to-coil connection wire, arranged in adjacent slots with overlapping wound portions, and a rotor positioned through a gap, allowing for reduced coil end size and improved space factor and heat dissipation by eliminating the need for additional wire terminals and enabling easier coil insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire terminals are arranged and welded onto the side or top part of the coil ends, then electrical connections can be established, but the size of the coil ends increases, making it difficult to provide compact connection and arrangement
Solution Approach 1:
The patent transitions the wire terminal arrangement from the traditional side/top surface of coil ends to the end face dimension. By arranging wire terminals in a planar array on the coil end face and connecting them via conductive adhesive in the same plane, the design eliminates the need for protruding connections, thereby reducing coil end size while maintaining electrical connection reliability.
Solution Approach 2:
The patent merges the wire terminal arrangement with the coil end face itself, rather than treating them as separate components. The wire terminals are directly positioned on the coil end face and connected through conductive adhesive, integrating the electrical connection function into the coil end structure, which reduces overall size and simplifies the assembly.
2Productivity
If lap winding coils are continuously formed, then productivity is improved, but the coils pull each other, resulting in an increase in difficulty of the operation of inserting the coils into the slots
Solution Approach 1:
The patent applies a flexible insulating film to the coil insertion regions, which provides the necessary flexibility to accommodate the continuous formation process while maintaining proper coil shape. This flexible coating allows coils to be continuously formed without excessive pulling, while still enabling smooth insertion into slots by providing controlled deformation capability.
Solution Approach 2:
The patent applies insulation and flexible coating to the coils before the continuous formation process. This preliminary preparation ensures that the coils are ready for continuous manufacturing without requiring additional processing steps during insertion, thereby maintaining both productivity and ease of operation.
3Ease of manufacture
If a gap of 0.1 to 0.2 mm or more is required between the two coils, then assembly of continuous lap winding coil into slot is enabled, but the space factor and heat dissipation performance are limited
Solution Approach 1:
The patent uses a flexible insulating film that can deform during the insertion process, allowing coils to be pushed closer together without requiring the traditional 0.1-0.2mm gap. The film's flexibility enables the coils to accommodate the insertion force while maintaining electrical insulation, thereby increasing the space factor and improving heat dissipation performance.
Solution Approach 2:
The patent changes the physical state and properties of the insulation material by using a flexible film that can undergo deformation. This parameter change allows the insulation to adapt during insertion, reducing the required gap between coils from 0.1-0.2mm to a minimal distance, thereby maximizing space utilization and heat dissipation.
4Ease of operation
If the coil is deformed into a shape suitable for inserting it into the slot, then insertion is facilitated, but the slot insertion region may loosen or feaze, requiring additional fixation measures
Solution Approach 1:
The patent applies a flexible insulating film to the slot insertion region that provides both flexibility for deformation during insertion and sufficient structural integrity to prevent loosening. The film's unique properties allow it to accommodate the necessary shape changes while maintaining stable attachment to the coil, eliminating the need for additional fixation measures.
Solution Approach 2:
The patent uses a composite structure combining the coil conductor with a flexible insulating film material. This composite provides the dual functionality of allowing deformation for easy insertion while maintaining stability and preventing loosening of the slot insertion region, as the film adheres to the conductor and provides both flexibility and structural support.
Data Source
AI summary
A rotating electrical machine includes a stator including at least two element coils of the same phase each having a plurality of turns and connected to each other through a coil-to-coil connection wire, the element coils being arranged in adjacent slots, respectively; and a rotor rotatably provided to the stator through a gap. The element coils of the same phase are fitted in the adjacent slots so that wound around portions of the element coils partially overlap each other. The coil-to-coil connection wire connects at a coil end portion conductor wires extending from linear conductor wire portions of innermost wires of the element coils contained in the slots.