Stator, motor, compressor, air conditioner, and manufacturing method of stator
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Solution Overview
Problem
Conventional stators employing distributed winding have large coil ends, leading to high manufacturing costs and reduced motor efficiency, as reducing coil end size decreases the winding factor.
Innovation Solution
The stator design includes a stator core with slots and coils wound in distributed fashion, where adjacent winding portions are inserted into one slot and extend circumferentially, allowing for annular coil placement in different radial positions, reducing coil end size and maintaining a winding factor of 1 to enhance efficiency and lower manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If distributed winding is employed to suppress noise and vibration, then noise and vibration are reduced, but coil ends become large and manufacturing cost increases
Solution Approach 1:
The patent transitions from conventional planar coil arrangement to a three-dimensional configuration where coils are wound around a cylindrical core. This dimensional change allows coil ends to be positioned at different axial locations, reducing the projected area of coil ends in any single plane and thereby reducing manufacturing cost while maintaining distributed winding benefits for noise and vibration suppression.
Solution Approach 2:
The stator core is divided into multiple segments along the axial direction, with each segment containing a set of coils. This segmentation allows the overall coil structure to be distributed across multiple axial positions, reducing the concentration of coil ends at any single location and thereby reducing manufacturing complexity and cost while maintaining the distributed winding configuration.
2Ease of manufacture
If coil end size is reduced to lower manufacturing cost, then manufacturing cost decreases, but winding factor decreases and motor efficiency decreases
Solution Approach 1:
By utilizing the axial dimension of the cylindrical core, the patent distributes coil ends across multiple axial positions rather than concentrating them in a single plane. This maintains an effective winding factor close to 1 while reducing the projected area of coil ends, thereby lowering manufacturing cost without sacrificing motor efficiency.
Solution Approach 2:
The patent optimizes the winding configuration by adjusting the number of turns, coil pitch, and axial distribution of coils to maintain a winding factor of approximately 1. This parameter optimization ensures high motor efficiency while allowing for reduced coil end dimensions and lower manufacturing cost.
3Area of stationary object
If more winding portions are inserted into one slot to reduce coil end size, then coil end size is reduced, but winding complexity increases
Solution Approach 1:
The patent resolves the complexity issue by utilizing the axial dimension of the cylindrical core. Instead of inserting multiple winding portions into a single slot at the same axial position, coils are distributed across multiple axial positions, reducing the number of winding portions per slot while maintaining compact coil end dimensions. This simplifies the winding process while achieving the desired reduction in coil end size.
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 reduces coil end size, decreases electrical resistance, and improves motor efficiency by efficiently using magnetic flux, while simplifying the winding process and reducing manufacturing costs.
Implementation Method 1
a first coil and a second coil of different phases which are wound on the stator core in distributed winding... The coils are arranged dispersedly in the circumferential direction... winding factor is 1
Data Source
AI summary
A stator includes a stator core having a plurality of slots in a circumferential direction about an axis and having an end surface in a direction of the axis, and a first coil and a second coil of different phases which are wound on the stator core in distributed winding. A winding factor is 1. Each of the first coil and the second coil has winding portions, the number of which corresponds to the number of poles. The winding portions include first and second winding portions adjacent to each other in the circumferential direction. The first and second winding portions are inserted into one slot of the plurality of slots and extend from the one slot to both sides in the circumferential direction on the end surface. The first and second coils are annularly disposed in different positions in a radial direction about the axis on the end surface.