Concentric Pin Stator Windings for Simpler Motor Manufacturing
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Solution Overview
Problem
Existing electric machine stators with pin windings are challenging to manufacture efficiently.
Innovation Solution
The stator design features pins arranged on concentric circles in slots, with specific connections between pins in different layers to form efficient windings, allowing for easy manufacturing and effective electromagnetic field generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If pins are arranged in slots with specific connections to form windings, then electromagnetic field efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The pins are pre-assembled into double pins or U-pins with predetermined connections before insertion into the stator slots. This preliminary preparation of connection structures simplifies the manufacturing process by reducing on-site assembly complexity while maintaining the efficient winding configuration required for optimal electromagnetic field generation.
Solution Approach 2:
Double pins and U-pins serve as intermediary structures that pre-establish the complex connections between multiple pins. These intermediary components simplify the overall manufacturing process by consolidating multiple connection operations into single insertion actions, thereby reducing manufacturing complexity while achieving the desired winding efficiency.
2Ease of manufacture
If multiple connection types are used for pins on different end faces, then ease of manufacture is improved, but device complexity increases
Solution Approach 1:
Different connection types (welding, double pins, U-pins) are applied locally to specific end faces or specific pin positions based on manufacturing requirements. This localized application of different connection methods allows optimization of ease of manufacture for each region while managing overall device complexity through targeted rather than universal application.
3Productivity
If pins are connected by welding or pre-bent configurations, then manufacturing speed is improved, but manufacturing precision requirements increase
Solution Approach 1:
Connections are pre-established through welding or pre-bending of pins before final assembly into the stator. This preliminary connection work allows for controlled precision operations in a dedicated manufacturing step, improving overall manufacturing speed while managing precision requirements through specialized pre-assembly processes rather than requiring high precision during final assembly.
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 design simplifies the manufacturing process and enhances the efficiency of the electromagnetic field, making it suitable for electric motors in vehicles.
Implementation Method 1
The windings may be formed from isolated copper rods in the form of what are referred to as pins... four pins in different layers are connected to one another in series and form a winding
Data Source
AI summary
A stator for an electric machine having a plurality of pins, which are arranged on concentric circles at different distances from a stator center point in slots in the stator, and each concentric circle forms a layer, where four pins in different layers are connected to one another in series and form a winding. A first pin of the winding is located in a first slot in the 4n-3 layer, wherein n is a natural number, a second pin of the winding is located in a second slot in the 4n-2 layer, wherein the second slot is at a first radial distance from the first slot in a first circumferential direction of the stator, a third pin of the winding is located in the first slot in the 4n layer, and a fourth pin of the winding is located in the second slot in the 4n-3 layer.