Delta-Wye Stator Coil Configuration for Automotive Alternators
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Solution Overview
Problem
Conventional automotive alternators face challenges in adjusting stator coil configurations to meet diverse output requirements across different speed regions, leading to increased manufacturing costs, part types, and man-hours due to limitations in the number of turns and connections, which restrict the degree of freedom in selecting stator coil specifications.
Innovation Solution
A rotating electric machine with a stator coil comprising Δ-Y connections formed by a Δ-connected first three-phase winding and a Y-connected second three-phase winding, where the number of turns of each winding can be set to different odd numbers, allowing for various combinations without altering the stator core or electric power conversion device specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of turns of the stator coil is increased to increase output in low-speed operating region, then the output in low-speed region is improved, but the total number of turns increases leading to increased manufacturing complexity and cost
Solution Approach 1:
The stator coil is divided into multiple independent Δ-Y connection units, each capable of having different numbers of turns. This segmentation allows the system to achieve high total turns for low-speed output without requiring a single complex winding structure, thereby reducing manufacturing complexity while maintaining the desired output characteristics.
2Adaptability or versatility
If different configurations of stator coil are used to meet diverse output requirements, then the adaptability is improved, but the number of part types increases leading to increased manufacturing cost
Solution Approach 1:
The patent designs multiple Δ-Y connection units that share common structural features and connection methods, allowing them to be manufactured using the same processes and tools. Each unit is universally designed with standardized terminals and mounting interfaces, enabling flexible combination to meet diverse output requirements without increasing the number of unique part types, thus maintaining manufacturing efficiency while achieving high adaptability.
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 configuration enhances the degree of freedom in selecting stator coil specifications, allowing for increased output and efficiency in both high-speed and low-speed operating regions without increasing manufacturing costs or part types, and simplifies the connection process.
Implementation Method 1
an automotive alternator which includes a stator coil that is formed by connecting a plurality of electric conductor segments
Data Source
AI summary
A rotating electric machine includes a hollow cylindrical stator core and a stator coil mounted on the stator core. The stator core has a plurality of slots that are arranged in a circumferential direction of the stator core. The stator coil is formed of a plurality of substantially U-shaped electric conductor segments to include at least one Δ-Y connection. The Δ-Y connection includes a Δ-connected first three-phase winding and a Y-connected second three-phase winding. The first three-phase winding includes three phase windings that are Δ-connected to define three terminals of the first three-phase winding therebetween. The second three-phase winding includes three phase windings that are respectively connected to the three terminals of the first three-phase winding. Further, the number of turns of the first three-phase winding and the number of turns of the second three-phase winding are respectively set to two different odd numbers.