Concentric Pin Stator Winding Layout for Reduced Harmonics
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Solution Overview
Problem
The existing manufacturing processes for stators with windings made from pins in electric machines are complex and do not efficiently produce a winding that minimizes electromagnetic field harmonics and torque ripples, leading to suboptimal performance in electric motors.
Innovation Solution
A stator design featuring pins arranged on concentric circles in slots, with specific connection types between pins to form efficient windings that reduce harmonics and torque fluctuations, allowing for easy manufacturing and improved NVH properties, and enabling the formation of partial coils that can be connected in parallel for efficient electromagnetic field generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manufacturing processes are used for stators with pin windings, then the manufacturing process is complex, but the winding does not efficiently minimize electromagnetic field harmonics and torque ripples
Solution Approach 1:
The stator is divided into multiple layers (first layer, second layer, third layer, etc.) with pins arranged on concentric circles at different radial distances. Each layer contains pins in specific slots following a systematic pattern (6n-1, 6n, 6n-2, 6n-3, 6n-5, 6n-4 layers), which segments the complex winding structure into manageable, repeatable units that reduce manufacturing complexity while improving electromagnetic field quality
Solution Approach 2:
The pins are pre-positioned in specific slots of specific layers before assembly, following a predetermined pattern. The first pin is located in a first slot in the 6n-1 layer, the second pin in a second slot in the 6n layer, and so on. This preliminary arrangement ensures optimal electromagnetic field generation and minimizes harmonics and torque ripples before the winding is completed
2Reliability
If pins are arranged in a systematic pattern on concentric circles, then electromagnetic field quality improves, but the manufacturing precision requirements increase
Solution Approach 1:
The pins are arranged on concentric circles around the stator center, creating equipotential patterns in the electromagnetic field. Each pin in a layer is at a specific radial distance from the stator center, and the systematic angular distribution (slots 6n-1, 6n, 6n-2, etc.) ensures uniform field distribution, improving electromagnetic efficiency while maintaining manageable precision requirements through geometric symmetry
3Object-affected harmful factors
If complex connection types are used between pins, then manufacturing difficulty increases, but the ability to reduce torque ripples and improve NVH properties improves
Solution Approach 1:
The pin arrangement and connection types are designed to automatically reduce torque ripples and improve NVH properties through the inherent geometry of the winding pattern. The systematic connection of pins across layers (connecting pins between adjacent layers through slot insulation) creates a self-regulating electromagnetic field that minimizes harmonics and torque fluctuations without requiring complex additional components or adjustment mechanisms
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 results in a stator with reduced disturbing harmonics and torque ripples, improved NVH properties, and simplified manufacturing, enabling efficient electromagnetic field generation and uniform rotating fields, suitable for electric machines in vehicles.
Implementation Method 1
The connection types establish an electrically conductive connection between the pins in the slots... The rotating field generated by such a winding has fewer disturbing harmonics
Data Source
AI summary
A stator for an electric machine includes a plurality of pins arranged on concentric circles at different distances to a stator center in slots, each concentric circle forming a layer, wherein six pins in different layers are serially connected to one another and form a winding. A first pin is located in a first slot in the 6n-1 layer, wherein n is an integer. A second pin is located in a second slot in the 6n layer, wherein the second slot has a first radial distance to the first slot in a first circumferential direction of the stator. A third pin is located in a third slot in the 6n-2 layer. A fourth pin is located in a fourth slot in the 6n-3 layer. A fifth pin is located in the first slot in the 6n-5 layer. A sixth pin is located in the second slot in the 6n-4 layer.