Distributed Lap Winding for Alternator Stators
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Solution Overview
Problem
Existing methods for producing windings for polyphase electrical machines, such as those used in generators, face challenges in efficiently creating a continuously wound distributed lap winding that can be seamlessly integrated into flatpack stator cores, particularly in achieving uniform conductor distribution and maintaining structural integrity during the rounding process.
Innovation Solution
A method involving the continuous winding of loops with loop connectors arranged on one side, allowing for rotation and folding to fit directly into stator slots, ensuring even conductor distribution and forming a symmetrical, multilayered configuration that enhances the structural integrity and roundness of the stator core when formed into a cylindrical ring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a distributed lap winding is wound continuously for flatpack stators, then the winding can be seamlessly integrated into the stator core, but achieving uniform conductor distribution and maintaining structural integrity during rounding becomes difficult
Solution Approach 1:
The winding is prepared in a flat configuration with predetermined loop connectors and connector holders before the rounding process. The loop connectors are pre-positioned and secured in connector holders, ensuring proper alignment and distribution before the stator core is formed into a cylindrical shape. This preliminary arrangement prevents distortion and maintains structural integrity during the rounding operation.
Solution Approach 2:
Connector holders are introduced as intermediary components to secure and position the loop connectors during the winding and rounding processes. These holders act as mediators that maintain the spatial relationship between conductors and prevent displacement during rounding, ensuring uniform conductor distribution while protecting the structural integrity of the winding assembly.
2Productivity
If loop connectors are arranged on one side with continuous winding, then production efficiency is improved, but ensuring even conductor distribution and symmetrical configuration becomes challenging
Solution Approach 1:
The continuous winding is divided into discrete loops, each with its own loop connector secured in a connector holder. This segmentation allows each loop to be independently positioned and secured while maintaining the overall continuous winding structure. The connector holders are arranged in a pattern that ensures even conductor distribution across the stator core, combining the efficiency of continuous winding with the precision of discrete positioning.
3Stability of the object's composition
If the stator core is rounded into a cylindrical ring after winding insertion, then the structural symmetry is improved, but the winding overhangs may lose integrity and alignment
Solution Approach 1:
Winding overhangs are pre-positioned and secured in connector holders before the rounding operation. This preliminary securing ensures that the overhangs maintain their alignment and structural integrity throughout the rounding process, preventing displacement or damage while the stator core is formed into its final cylindrical shape.
Data Source
AI summary
Method for producing a distributed lap winding for polyphase systems, in particular for alternators, wherein, in a first step, a chain of laps is formed with a linking direction, characterized in that, in a further step, at least one lap is rotated with its lap sides at right angles to the linking direction such that at least one lap side of one lap is arranged alongside at least one lap side of another lap such that the at least one lap side of one lap and the at least one lap side of another lap are arranged at a position which corresponds to a slot position.