Electric Machine Distributed Winding Double Cross End Loops
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Solution Overview
Problem
Existing electric machine winding arrangements fail to provide improved power efficiency, cooling, and sinusoidal waveform with reduced harmonic emf and torque ripple, while also being cost-effective for manufacturing in various applications, including electric and hybrid-electric vehicles.
Innovation Solution
A stator winding arrangement with multiple parallel paths and end loops of different pitches distributed across contiguous slots, allowing for a balanced and efficient winding configuration that switches positions to optimize performance and reduce manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a conventional winding arrangement is used, then the manufacturing process is simple, but the power efficiency and cooling ability are insufficient
Solution Approach 1:
The winding is divided into multiple parallel paths (at least four) distributed across different slot sets, with each path having its own end loops. This segmentation allows for improved power efficiency and cooling through better current distribution and heat dissipation, while the modular structure facilitates systematic manufacturing
Solution Approach 2:
The winding arrangement utilizes multiple revolutions around the core (at least four revolutions including clockwise and counter-clockwise directions) with parallel paths switching positions between left and right slots. This multi-dimensional spatial arrangement optimizes electromagnetic performance and cooling while maintaining manufacturing feasibility through pattern repetition
2Manufacturing precision
If a conventional winding arrangement is used, then the manufacturing cost is low, but the sinusoidal waveform quality and harmonic reduction are insufficient
Solution Approach 1:
Different slot sets contain different parallel paths with specific arrangements optimized for their local position. The end loops have different pitches tailored to specific path requirements, enabling precise control of local electromagnetic characteristics to achieve superior sinusoidal waveform quality and reduced harmonics
Solution Approach 2:
The winding follows a periodic pattern with parallel paths making multiple revolutions (at least four) around the core in alternating clockwise and counter-clockwise directions. This periodic arrangement with systematic position switching creates balanced magnetic distributions that reduce torque ripple and improve waveform quality while facilitating repetitive manufacturing processes
3Temperature
If a winding arrangement with multiple parallel paths and different end loop pitches is used, then the cooling ability improves, but the device complexity increases
Solution Approach 1:
The winding is segmented into at least four parallel paths distributed across different slot sets, with each path having dedicated end loops of specific pitches. This segmentation creates multiple independent current channels that improve cooling efficiency through better heat distribution, while the modular segmented structure makes the complex arrangement manageable and manufacturable
Solution Approach 2:
The parallel paths dynamically switch positions between left and right slots during their revolutions around the core. This dynamic position switching optimizes the spatial distribution of conductors for improved cooling and electromagnetic performance, while the systematic dynamic pattern maintains manufacturing regularity
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 proposed winding arrangement enhances power efficiency, cooling, and reduces harmonic emf and torque ripple, while being cost-effective and suitable for diverse applications, including electric and hybrid-electric vehicles, by providing a balanced and efficient distribution of conductors across the stator slots.
Implementation Method 1
Electric machines are designed to meet specific operating requirements depending on the intended application the electric machine
Data Source
AI summary
An electric machine a stator having a stator core and windings positioned thereon. The stator core has a plurality of slots formed therein and a winding positioned in the plurality of slots. The winding includes at least four parallel paths distributed in slot sets of the stator core. Each slot set includes at least four contiguous slots including two left slots and two right slots. A first parallel path and a second parallel path are arranged in the two left slots for at least a first revolution of the winding around the core. The first parallel path and the second parallel path are arranged in the two right slots for at least a subsequent revolution of the winding around the core.