Hairpin Stator Terminal Layout for Shorter Welding-End Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric machine stator windings face challenges in scalability and manufacturing efficiency due to complex terminal connections and uneven distribution of phase and neutral terminals, leading to increased axial length and complexity in welding operations.
Innovation Solution
A stator design featuring hairpin conductors with identical slot pitches, where leg portions are received in multiple layers and head portions extend out for connection, allowing phase and neutral terminals to be arranged at the welding end, facilitating a star or delta connection and reducing the terminal connection range by distributing them between outermost and innermost layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If phase terminals and neutral terminals are distributed unevenly in conventional stator windings, then manufacturing complexity increases, but axial length and welding operation complexity increase as well
Solution Approach 1:
The patent merges phase terminals and neutral terminals into a unified terminal arrangement at the welding end, consolidating previously distributed terminals into a compact configuration that reduces overall complexity while maintaining manufacturing efficiency
Solution Approach 2:
The patent redistributes terminals across multiple radial layers (innermost and outermost layers) rather than concentrating them in a single plane, utilizing the radial dimension to organize terminals and reduce circumferential connection range
2Length of moving object
If terminals are arranged in a compact configuration, then axial length is reduced, but terminal distribution complexity increases
Solution Approach 1:
The patent segments terminals into groups located at different radial layers (innermost and outermost layers), with each layer containing specific terminals that can be independently arranged and connected, reducing the axial space required while maintaining organizational simplicity
Solution Approach 2:
By utilizing the radial dimension to distribute terminals across multiple layers, the patent achieves compact axial length while organizing terminals in a systematic pattern that reduces arrangement complexity
3Adaptability or versatility
If hairpin conductors with identical slot pitches are used, then manufacturing scalability is improved, but flexibility in terminal positioning is reduced
Solution Approach 1:
The patent compensates for the reduced positioning flexibility from identical slot pitches by utilizing the radial layer dimension, allowing terminals to be positioned at different radial locations (innermost and outermost layers) while maintaining the standardized slot pitch for manufacturing scalability
Data Source
AI summary
A stator including a core having slots and a hairpin winding. The winding includes hairpin conductors with two legs connected at a head portion. A slot pitch between the two legs is defined by the head portion. The legs are received in the slots in two radially adjacent layers. The head portions extend from the core at an insertion end and end sections of the legs opposite the head portions extend from the core at a welding end. The winding defines three phase windings, each having at least one branch. Each branch has a phase terminal formed at one of the end sections for connecting to a phase busbar, and a neutral terminal formed at one of the end sections for connecting to a neutral busbar. The terminals are arranged at the welding end, in one of an outermost layer and an innermost layer of the radially adjacent layers.