Flat Copper Stator Winding Layout for Balanced Parallel Currents
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Solution Overview
Problem
Multi-layer flat copper wire windings in motors for new energy vehicles experience unbalanced current loops due to uneven electromagnetic coupling, leading to increased copper consumption and torque fluctuations, which negatively impact motor performance.
Innovation Solution
A 4-branch parallel winding structure is proposed for the stator winding of a three-phase AC motor, where the first and third branches have the same winding direction, and the second and fourth branches have the same direction opposite to the first and third, with specific connections between conductors in each phase to balance electromagnetic coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multi-layer flat copper wire wave windings are used to reduce AC copper consumption, then power density is improved, but unbalanced current loops are generated due to unequal electromagnetic coupling
Solution Approach 1:
The winding structure is divided into multiple independent parallel branches (first, second, third, and fourth parallel-winding branches) with alternating winding directions. This segmentation allows each branch to be independently optimized for electromagnetic coupling, balancing the current distribution across all branches while maintaining high power density through the multi-layer flat copper wire construction.
Solution Approach 2:
The invention employs asymmetric winding directions in alternating parallel branches - the first and third branches have one winding direction while the second and fourth branches have the opposite winding direction. This asymmetric arrangement compensates for unequal electromagnetic coupling in multi-layer windings, ensuring balanced current loops across all branches without sacrificing power density.
2Power
If parallel winding with multiple branches is used to match torque and voltage characteristics, then torque characteristics are improved, but unbalanced current loops cause torque fluctuation
Solution Approach 1:
The torque production is segmented across multiple parallel-winding branches with alternating winding directions. This segmentation ensures that each branch contributes均衡ly to the total torque, balancing the electromagnetic coupling forces and eliminating current-induced torque fluctuations while maintaining the required torque-voltage characteristics.
Solution Approach 2:
The alternating winding directions in adjacent parallel branches create counterbalancing electromagnetic forces. The asymmetric winding arrangement acts as a counterweight mechanism that compensates for unequal electromagnetic coupling, ensuring stable torque output by neutralizing imbalances that would otherwise cause torque fluctuations.
3Power
If 8-layer flat copper wire with 4 parallel-winding branches is used, then voltage characteristics are matched, but copper consumption increases due to unbalanced current loops
Solution Approach 1:
The 8-layer flat copper wire winding is segmented into 4 parallel-winding branches with alternating winding directions. This segmentation optimizes current distribution across all branches, eliminating unbalanced current loops that would otherwise require additional copper to compensate for losses, thereby maintaining voltage characteristics while minimizing actual copper consumption.
Solution Approach 2:
The invention changes the winding direction parameter in alternating parallel branches to create balanced electromagnetic coupling. This parameter change optimizes the current distribution and electromagnetic efficiency, reducing copper losses and actual copper consumption while maintaining the required voltage characteristics for the motor.
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 reduces electrical current loops, minimizes copper consumption, and enhances motor performance by balancing electromagnetic coupling, improving heat dissipation and power density.
Implementation Method 1
unbalanced current loop between the parallel-winding branches of the same phase will be generated due to unequal electromagnetic coupling
Implementation Method 2
The stator winding provides electrical energy input and magnetic field establishment for motor
Data Source
AI summary
A stator winding structure (100) for a motor. The motor is a three-phase alternating current motor having eight poles. Each phase comprises four shunt wound branches. The stator winding consists of multiple U-shaped flat copper wires (10). A connection portion of each U-shaped flat copper wire (10) disposed in the motor is located on the same side with respect to the motor. The technical solution also provides a motor comprising the stator winding structure (100) and a vehicle comprising the motor.