Hairpin Stator Winding Layout for Simpler Parallel Return Wiring
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Solution Overview
Problem
Conventional motor stators with hairpin-shaped wires have complex manufacturing processes due to the requirement of multiple parallel connected windings, which increases production complexity and axial space configuration.
Innovation Solution
A motor stator winding structure featuring a ring-shaped stator core with slot-positions arranged around a rotor accommodation space, where hairpin wires are inserted and extended to form parallel windings, with entry slot-positions of different phase windings located in distinct magnetic pole regions to simplify return connection wire design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple parallel connected windings are used with conventional hairpin-shaped wires, then the motor stator can achieve required electrical performance, but the manufacturing complexity and variety of wire types increases
Solution Approach 1:
The patent applies homogeneity by making all return connection wires identical in shape and specifications across different phases (U, V, W phases). This is achieved by strategically positioning entry slot-positions in different magnetic pole regions so that return connection wires of all phases have the same spatial path and dimensions, eliminating the need for multiple wire types and simplifying manufacturing while maintaining electrical performance
Solution Approach 2:
The patent uses asymmetry in the arrangement of entry slot-positions across different magnetic pole regions to achieve symmetric outcomes. By placing entry slot-positions asymmetrically in different pole regions (e.g., first phase in first pole region, second phase in second pole region, third phase in third pole region), the return connection wires naturally become identical in shape and size, reducing manufacturing complexity
2Reliability
If conventional winding arrangements are used, then electrical performance is achieved, but axial space configuration increases
Solution Approach 1:
The patent applies dimensionality change by transitioning from radial arrangement to axial arrangement of return connection wires. Instead of allowing return wires to extend radially or overlap in the radial direction, the invention positions entry slot-positions in different magnetic pole regions so that return wires protrude axially from the stator core, utilizing the axial dimension to separate wire paths and reduce radial overlap, thereby minimizing axial space configuration
Solution Approach 2:
The patent segments the return connection wires of different phases by positioning their entry slot-positions in different magnetic pole regions. This segmentation separates the wire paths spatially, preventing overlap and allowing each phase's return wire to be independently arranged, which simplifies the overall wiring structure and reduces axial space requirements
Data Source
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AI summary
A motor stator winding structure includes a stator core and slot-positions. The stator core includes an insertion side and an extension side. The hairpin wires are configured to be arranged into slot-positions of the phase slots of the same phases of the magnetic pole regions. A first phase winding includes first hairpin wires of the hairpin wires inserted from an entry phase slot-position of a first phase. A second phase winding includes second hairpin wires of the hairpin wires inserted from an entry phase slot-position of a second phase. A third phase winding includes third hairpin wires of the hairpin wires inserted from an entry phase slot-position of a third phase. The entry phase slot-position of the first phase, the entry phase slot-position of the second phase and the entry phase slot-position of the third phase are located in three different magnetic pole regions respectively.