Hairpin Stator Wire Layout for Easier Odd-Layer Welding
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Solution Overview
Problem
Conventional hairpin wire motor stators with odd-numbered slot-position layers face challenges in adjusting the wire span during welding, leading to increased difficulty and costs in manufacturing.
Innovation Solution
The proposed hairpin wire motor stator employs a ring-shaped stator core with radially-adjacent slot-position layers, utilizing various types of U-shaped and straight wires arranged in specific configurations to facilitate easy adjustment of wire span on both sides of the stator core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If U-shaped hairpin wires are joined at the same side of the motor iron core for welding convenience, then welding ease is improved, but wire span adjustment capability deteriorates
Solution Approach 1:
The wire arrangement is segmented into different types (first U-shaped wires for outermost layer, second U-shaped wires for innermost layer, third U-shaped wires for middle layers, and straight wires) that can be selectively applied to different slot-position layers. This segmentation allows the wire span to be adjusted by choosing appropriate wire types for different layers while maintaining welding convenience at the same side.
Solution Approach 2:
The solution moves from a single-layer wire arrangement to a multi-layer radial arrangement with M radially-adjacent slot-position layers. By distributing wires across multiple radial layers and using different wire configurations for different layers, the patent achieves both welding convenience and wire span adjustability that cannot be achieved in a single layer.
2Adaptability or versatility
If complex wire arrangements are used to adjust wire span in odd-numbered slot-position layers, then wire span adaptability is improved, but manufacturing complexity increases
Solution Approach 1:
The complex wire arrangement problem is solved by segmenting the slot-position layers into radial groups and assigning specific wire types to specific layers. This segmentation simplifies the overall arrangement by creating repeatable patterns for each layer type, reducing the complexity of achieving wire span adaptability in odd-numbered layers.
Solution Approach 2:
The patent introduces flexibility into the wire arrangement by allowing different wire types (U-shaped and straight) to be used in different radial layers. This dynamic configuration enables the wire span to be adjusted according to the specific requirements of odd-numbered slot-position layers without requiring a completely complex arrangement throughout.
3Ease of manufacture
If conventional wire arrangements are used in odd-numbered slot-position layers, then manufacturing simplicity is maintained, but welding difficulty increases
Solution Approach 1:
By segmenting the wire arrangement into layer-specific configurations, the patent maintains manufacturing simplicity through standardized wire types for each layer while solving the welding difficulty in odd-numbered layers. Each layer type has a predetermined wire arrangement that is simple to manufacture but optimized for welding accessibility.
Solution Approach 2:
The patent applies local quality by tailoring the wire arrangement specifically for odd-numbered slot-position layers versus even-numbered layers. The wire span and configuration are locally optimized for layers that require welding, ensuring that welding difficulty is addressed where it occurs without complicating the entire wire arrangement system.
Data Source
AI summary
A hairpin stator includes a core, slot-positions and hairpin wires. The core includes a first side and a second side. The slot-positions are configured on the core circumferentially to form M radially-adjacent slot-position layers, wherein M is an odd number greater than or equal to 5. The hairpin wires are configured in the slot-positions and connected to form a plurality of windings. The hairpin wires include a plurality of first U-shaped wires arranged at an outermost slot-position layer in the radial direction and a plurality of second U-shaped wires arranged at an innermost slot-position layer in the radial direction. Each first U-shaped wire includes a U-shaped section arranged at the outermost slot-position layer and protruding from the first side of the core. Each second U-shaped wire includes a U-shaped section arranged at the innermost slot-position layer and protruding from the second side of the core.