Hairpin Stator Winding Layout for Balanced Parallel Voltages
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Solution Overview
Problem
Conventional hairpin wire motor stators face challenges in balancing voltages of parallel-connected windings to avoid circulating currents, leading to increased complexity in manufacturing due to the need for various wire sizes and spans.
Innovation Solution
A hairpin wire motor stator design featuring a ring-shaped stator core with slot-positions arranged circumferentially, allowing hairpin wires to be inserted and protruded, forming windings that span across multiple phase slots with a consistent span equal to the total number of phase slots divided by the number of polar regions plus or minus one, thereby eliminating the need for multiple wire types and reducing production complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple parallel-connected windings are used in conventional hairpin wire motor stators, then voltage balance can be achieved, but circulating currents are generated and manufacturing complexity increases
Solution Approach 1:
The patent applies homogeneity by using hairpin wires with uniform span and cross-sectional dimensions throughout the stator. All windings are formed using identical wire specifications, eliminating the need for multiple wire types. This uniform approach ensures equal voltage distribution across parallel windings, preventing circulating currents while simplifying manufacturing processes.
2Reliability
If various hairpin-shaped wires with different sizes or spans are used, then circulating currents can be avoided, but the complexity of motor stator manufacturing increases
Solution Approach 1:
The patent implements universality by designing a single type of hairpin wire that serves multiple functions across different positions in the stator. The unified wire design with consistent span and dimensions allows the same component to be used throughout the assembly, eliminating the need for multiple specialized wire types. This approach prevents circulating currents through proper winding configuration while maintaining manufacturing simplicity.
3Ease of manufacture
If a single type of hairpin wire is used, then manufacturing complexity is reduced, but voltage balance and circulating current prevention become challenging
Solution Approach 1:
The patent applies parameter changes by carefully selecting and maintaining specific geometric parameters of the hairpin wires, particularly the span length and cross-sectional dimensions. By optimizing these parameters and keeping them consistent across all wires, the design achieves proper voltage distribution and circulating current prevention using a single wire type. The key is in the precise parameter selection rather than varying parameters across different wire types.
Data Source
AI summary
A hairpin stator includes an iron core, a plurality of slot-positions and a plurality of hairpin wires. The slot-positions are located in the circumferential direction of the iron core, and form a plurality of adjacent slot-position layers in the radial direction. The iron core includes polar regions, each polar region includes phases, and each phase includes phase slots. The hairpin wires are arranged in the slot-positions of the phase slots of the same phases of the polar regions, and the hairpin wires are connected to form windings. The hairpin wires include transpolar hairpin wires. A span of the transpolar hairpin wires on an insertion side of the iron core is equal to a quotient, which is obtained by dividing a total number of the phase slots by a total number of the polar regions, plus 1 or minus 1.