Stator, electric motor, compressor, air conditioner, and stator manufacturing method
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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 due to a lower winding factor.
Innovation Solution
A stator design with a stator core having slots in the circumferential direction, where coils of different phases are wound in distributed winding, with winding portions corresponding to the number of poles, allowing adjacent winding portions to be inserted into one slot and extending from it in both directions, thereby reducing coil end size and improving winding factor to 1.
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 arrangement where coils are disposed at different radial positions. The first coil is positioned at a first radial position and the second coil at a second radial position, creating a layered structure that reduces coil end size while maintaining distributed winding benefits for noise and vibration suppression.
Solution Approach 2:
The patent implements a nested arrangement where the first coil and second coil are disposed concentrically at different radial positions around the stator core. The inner coil is effectively nested within the radial space of the outer coil, optimizing space utilization and reducing the overall coil end dimensions while preserving the distributed winding configuration.
2Ease of manufacture
If coil ends are reduced in size to lower manufacturing cost, then manufacturing cost decreases, but winding factor decreases and motor efficiency decreases
Solution Approach 1:
By arranging coils in different radial dimensions rather than merely reducing their size in the planar direction, the patent achieves both compact coil ends and optimal winding factor. The first coil at a first radial position and second coil at a second radial position create overlapping magnetic flux paths that maintain high winding factor while reducing coil end size.
Solution Approach 2:
The patent optimizes the radial positions of the first and second coils to achieve a winding factor of 1. By carefully selecting the radial distances and angular positions of the coils, the magnetic flux linkage is maximized, ensuring high motor efficiency despite the reduced coil end dimensions.
3Object-affected harmful factors
If conventional distributed winding is used, then noise and vibration are suppressed, but coil arrangement complexity increases
Solution Approach 1:
The patent simplifies coil arrangement by utilizing the radial dimension, placing the first coil at a first radial position and the second coil at a second radial position. This vertical layering approach is more straightforward than complex planar arrangements, reducing the number of winding operations required while maintaining noise and vibration suppression through distributed winding.
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 manufacturing costs, and enhances motor efficiency by optimizing coil arrangement and winding factor, facilitating efficient use of magnetic flux and reducing electrical resistance.
Implementation Method 1
a first coil and a second coil of different phases which are wound on the stator core in distributed winding
Implementation Method 2
The first winding portion and the second winding portion 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
Data Source
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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, the number of which corresponds to the number of poles, include a first winding portion and a second winding portion that are adjacent to each other in the circumferential direction. The first winding portion and the second winding portion 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 coil and the second coil are annularly disposed in different positions in a radial direction about the axis on the end surface of the stator core.