Five-Phase Generator Winding Layout for Noise Reduction
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Solution Overview
Problem
Multi-phase electrical machines, such as generators, face challenges with magnetic noise, flow noise, and manufacturing precision due to a high number of slots, which limits wire diameter and increases the likelihood of wire damage during assembly.
Innovation Solution
A five-phase electrical machine design with a stator core having a circumferential slot pitch and a winding arrangement where the number of slots corresponds to a multiple of the number of phases, allowing for larger wire diameters and improved manufacturing tolerance, using distributed windings and loop or wave windings with optimized slot widths and yoke heights to reduce noise and enhance robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a high number of phases (six-phase or two-times three-phase system) is used, then the magnetic noise is reduced, but the number of slots increases which limits the wire diameter and increases manufacturing complexity
Solution Approach 1:
The patent changes the phase configuration parameter from six-phase or two-times three-phase to five-phase system. This parameter change reduces the number of slots required while maintaining noise reduction benefits, thereby allowing larger wire diameters and simplifying the overall device structure.
Solution Approach 2:
The patent implements a specific winding arrangement where windings are distributed in layers at different radial positions within the stator slots. This local optimization of winding placement improves space utilization and allows for larger wire diameters in a five-phase configuration, resolving the contradiction between slot count and wire size.
2Object-affected harmful factors
If a high number of phases is used, then the magnetic noise is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
By changing the phase system from six-phase to five-phase, the patent reduces the number of windings and slots, which directly lowers the cumulative tolerance requirements. Fewer components mean fewer sources of manufacturing variation, thereby reducing the overall precision requirements while maintaining electromagnetic performance.
3Adaptability or versatility
If the number of slots is increased, then the number of phases is increased, but the wire diameter is limited and mechanical resilience is reduced
Solution Approach 1:
The patent optimizes the phase configuration parameter to five phases, which provides an optimal balance between electrical performance and mechanical strength. This configuration allows for larger wire diameters with adequate mechanical resilience while maintaining high adaptability for different applications.
Solution Approach 2:
The patent employs a layered winding arrangement where windings are positioned at different radial levels within the stator. This local structural optimization allows for larger individual wire diameters that enhance mechanical strength, while the five-phase configuration maintains the required electrical adaptability.
4Ease of manufacture
If prefabricated windings are used to simplify manufacturing, then assembly is easier, but the number of windings increases complexity
Solution Approach 1:
By reducing the phase system to five phases, the patent decreases the total number of windings required compared to six-phase systems. This parameter change makes the use of prefabricated windings more practical and cost-effective, as fewer complex components need to be manufactured and assembled.
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 design reduces magnetic and flow noise, improves performance and efficiency by minimizing ripple in the rectified generator voltage, and allows for a more cost-effective and precise manufacturing process with increased mechanical resilience and reduced assembly forces.
Implementation Method 1
electromagnetic forces create unwanted magnet noise
Implementation Method 2
a stator which has a core body having a circumferential slot pitch and a winding arrangement with a plurality of windings forming phases
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a polyphase electrical machine, in particular a polyphase generator with a stator, which has a core element having a circumferential slot pitch and a winding arrangement with a plurality of windings. It is provided that each winding (45, 46, 47, 48, 49) and each slot (35, 36, 37, 38, 39) of the group of slots extending over a pole pitch is associated with one of the phases, and the windings (45, 46, 47, 48, 49) have winding sections (55) lying in associated slots (35, 36, 37, 38, 39), between which winding sections in each case one end winding connection (56) is formed, wherein the end winding connections (56) of different windings (45, 46, 47, 48, 49) are arranged radially with respect to one another in terms of position, and the number of phases is five. Furthermore, the invention relates to a method for producing a polyphase electrical machine.