EV Drive Motor Winding Layout for Shorter Axial Length
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Solution Overview
Problem
The design of electric vehicle drives, such as trucks and buses, is limited by the axial length of the stator's end winding system, which requires complex insulation measures due to spatial proximity of voltage potentials, increasing installation space and complicating compact vehicle design.
Innovation Solution
A compact dynamo-electric machine design with a polyphase winding system where the star point is radially positioned above the end windings, and winding caps guide phase conductors and the star point, reducing the need for axial insulation and allowing for a more compact structure with improved thermal management through cooling ribs or tubes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the circuit arrangements are positioned in the axial elongation of the end winding, then the electrical connections are established, but the axial length of the stator increases and complex insulation measures are required
Solution Approach 1:
The patent repositions the star point from the axial direction to the radial direction, specifically placing it in the air gap between the rotor and stator. This dimensional change allows electrical connections to be established without extending the axial length of the stator, thereby resolving the contradiction between ease of manufacture and axial length.
Solution Approach 2:
The patent introduces an insulating support structure that serves as an intermediary element. This support structure holds the star point conductor in the air gap and provides integrated insulation, eliminating the need for complex insulation measures while maintaining proper electrical connections. The insulating support acts as a mediator between the star point and surrounding conductive parts.
2Reliability
If complex insulation measures are implemented to achieve desired electric strength, then electrical safety is ensured, but the necessary installation space increases
Solution Approach 1:
The patent combines the insulation function with the mechanical support function into a single insulating support structure. This merged component provides both structural support for the star point conductor and the necessary electrical insulation, thereby ensuring electric strength without increasing installation space. The consolidation of functions eliminates the need for separate insulation elements.
Solution Approach 2:
The insulating support structure serves as an intermediary that provides integrated insulation between the star point and surrounding conductive parts. This single intermediary element ensures the desired electric strength while occupying minimal space, avoiding the need for multiple separate insulation components that would increase installation volume.
3Volume of stationary object
If the axial length of the stator is reduced for compact vehicle design, then space for payload and passengers increases, but the positioning of circuit arrangements becomes more difficult
Solution Approach 1:
The patent positions the star point in the radial direction within the air gap, rather than in the axial direction. This dimensional change allows circuit arrangements to be properly positioned and connected without requiring extended axial length, thereby enabling compact stator design while maintaining ease of manufacturing and assembly.
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 results in a more compact and thermally efficient dynamo-electric machine, optimizing space for payload and passengers by minimizing the volume of drive components, while maintaining effective insulation and electric strength.
Implementation Method 1
As a result of an electromagnetic interaction between an energized winding system of a stator and a rotor, dynamo-electric machines generate a torque
Implementation Method 2
improved thermal management through cooling ribs or tubes
Implementation Method 3
improved thermal management through cooling ribs or tubes
Data Source
AI summary
An electrically driven single-axle or multiple-axle bus or truck having at least one dynamoelectric machine. At least one axle can be driven by at least one dynamoelectric machine. The dynamoelectric machine has a stator located in a housing and has a winding system arranged in slots situated in the region of an air gap. The winding system is of polyphase design and forms end windings at the end sides of the stator. Conductors of the electrical phases are arranged axially directly on the end winding. A conductor of a star-point of the polyphase winding system is provided radially over the end windings between the end winding and the housing. The end windings are each provided with a winding cap. The winding cap guides electrical conductors of the winding system and/or phase lines and/or star-point lines.