Hairpin Stator Winding Layout With Common-End Terminal Connections
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Solution Overview
Problem
Conventional electrical machine stator winding arrangements using hairpin windings result in significant space consumption, weight, and electrical losses due to extensive interconnecting wiring, particularly when connecting coils from inner to outer radial positions.
Innovation Solution
A coil configuration for electrical machine stators formed from hairpin wires with pairs of legs passing through slots on opposing radial faces, allowing for reduced volume, weight, and losses by positioning input and output terminals on a common end of the tooth, enabling n full turns around the tooth element with n+1 hairpin wires and n electrical connections between adjacent pairs across the axial face.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional hairpin windings are used with extensive interconnecting wiring to connect coils from inner to outer radial positions, then complete coil connections are achieved, but space consumption, weight, and electrical losses increase significantly
Solution Approach 1:
The coil is segmented into multiple hairpin wires (n+1 hairpins) with pairs of legs passing through slots on opposing radial faces. Each hairpin is inserted through adjacent slots either side of a tooth, and the free ends are bent and electrically connected to form continuous windings. This segmentation allows the coil to be constructed from discrete units that can be independently positioned and connected, reducing the need for extensive interconnecting wiring.
Solution Approach 2:
The patent transitions from conventional radial connections to axial connections by positioning input and output terminals on a common end of the tooth. The hairpin wires extend axially through the slots, with terminal connections made at the axial ends rather than requiring radial interconnections. This dimensional change from radial to axial connectivity eliminates the need for complex interconnecting wiring between inner and outer radial positions.
2Reliability
If conventional hairpin windings with extensive interconnecting wiring are used, then complete coil connections are achieved, but weight increases
Solution Approach 1:
The patent transitions from radial to axial terminal connections, positioning both input and output terminals on a common axial end of the tooth. This eliminates the need for heavy interconnecting wiring that would otherwise be required to connect coils from inner to outer radial positions, significantly reducing the overall winding weight while maintaining complete electrical connectivity.
Solution Approach 2:
The terminal connections for multiple hairpin wires are merged at the common axial end of the tooth. The n+1 hairpin wires are electrically connected in sequence, with their free ends bent and joined to form continuous windings, consolidating multiple connection points into a single axial location and reducing the total amount of interconnecting material required.
3Reliability
If conventional hairpin windings with extensive interconnecting wiring are used, then complete coil connections are achieved, but electrical losses increase
Solution Approach 1:
By repositioning terminal connections from radial to axial locations, the patent minimizes the length and complexity of interconnecting wiring. The hairpin wires extend axially through the slots with terminals at the axial ends, creating shorter and more direct electrical paths. This reduces the total conductor length and minimizes resistive electrical losses while maintaining complete coil connections.
4Manufacturing precision
If slots have 2n+2 slot positions to accommodate n full turns of hairpin wires, then complete winding coverage is achieved, but slot space consumption increases
Solution Approach 1:
The slot is divided into 2n+2 discrete slot positions to accommodate the n+1 hairpin wires with precise positioning. Each hairpin wire occupies specific slot positions, with half of the slot positions filled by coil wires and the other half available for adjacent coils. This segmentation enables precise winding coverage while optimizing slot space utilization through systematic arrangement.
Solution Approach 2:
The slot positions are designed to serve multiple functions: accommodating hairpin wires from the current coil, providing space for adjacent coils, and enabling systematic electrical connections. The 2n+2 slot positions create a universal structure that can accommodate different winding configurations and support both radial and axial flux machine types, maximizing space utilization efficiency.
Data Source
AI summary
The disclosure relates to winding arrangements for electrical machine stators. Example embodiments include a coil for a tooth element of an electrical machine stator, the coil formed from a plurality of hairpin wires having pairs of legs passing through first and second slots on opposing radial faces of the tooth element, the coil having n full turns passing around the tooth element, the first and second slots each having 2n+2 slot positions having a depth d′ for accommodating a single hairpin wire, the slots each having a first slot position at a first common end and a 2n+2th slot position at a second opposing end, the coil having first and second terminal connections connected to hairpin wires extending through the first and second slots at respective first and second slot positions.