Flat-Wire Stator Coil Layout for Lower Winding End Height
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing flat wire motors face challenges in simplifying the wire-embedded structure and reducing the height of the winding end, leading to increased complexity and risk of insulation failure due to high coil height and limited space.
Innovation Solution
A stator design incorporating long-pitch and short-pitch coils with concentric embedded arrangements, reduced wire types, and simplified connection methods, including extension portions for efficient coil embedding and reduced height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If traditional wire embedding structure is used, then the motor can achieve basic functionality, but the winding end height increases and the structure becomes complex
Solution Approach 1:
The patent divides the winding structure into distinct plug portions and connection portions, with each having specific functions. The plug portions are inserted into slots while connection portions are welded together, segmenting the embedding process and reducing overall height while maintaining structural integrity
Solution Approach 2:
The patent transitions from traditional planar winding arrangements to a three-dimensional concentric arrangement where plug portions extend radially into slots and connection portions connect axially. This dimensional change allows for compact height while preserving electrical connectivity
2Adaptability or versatility
If more wire types are used for different coil configurations, then various voltage and power ranges can be adapted, but the wire embedding process becomes more complex
Solution Approach 1:
The patent designs a universal plug portion structure that can be used across different coil configurations and voltage/power ranges. The same basic plug and connection portion design serves multiple functions, eliminating the need for specialized wire types for different applications while maintaining manufacturing simplicity
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A flat wire motor and a stator thereof are provided. The stator includes a stator iron core and a stator winding provided at the stator iron core. The stator iron core has a plurality of winding slots formed in an inner wall of the stator iron core. The stator winding includes a plurality of coil elements, and the plurality of winding slots is arranged along a circumferential direction of the inner wall of the stator iron core. Each of the plurality of coil elements includes a first coil and a second coil, the first coil includes a first plug portion, a second plug portion, and a first connection portion connecting the first plug portion and the second plug portion, and the second coil includes a third plug portion, a fourth plug portion, and a second connection portion connecting the third plug portion and the fourth plug portion. The first plug portion, the third plug portion, the fourth plug portion, and the second plug portion are arranged along the circumferential direction and respectively inserted in different winding slots of the plurality of winding slots, the first plug portion is connected to the fourth plug portion, and the second connection portion is located on a side of the first connection portion facing towards the stator iron core. The embodiments of the present disclosure can simplify the wire embedded process and reduce the height of a stator winding end.