Hairpin Stator Winding Layout for Adjustable Turn Counts
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Solution Overview
Problem
Conventional hairpin winding technologies for electrical machines lack flexibility in adjusting the number of turns without significant modifications to the manufacturing process, making it difficult to produce motors for different power or torque classes without setting up separate production facilities.
Innovation Solution
The solution involves varying or combining the jump widths of conductor clamps for at least two conductor clamp groups, allowing for modifications in the winding configuration from parallel to series connections, enabling the adjustment of the number of turns with minimal changes to the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the same combination of jump widths is used for all conductor clamp groups, then the winding pattern is fixed and manufacturing is simplified, but the number of turns cannot be adjusted without setting up separate production facilities
Solution Approach 1:
The patent applies local quality by allowing different conductor clamp groups to have different jump width combinations. Specifically, while most conductor clamp groups use a standard jump width combination, at least two conductor clamp groups use a different variation or combination of jump widths. This localized modification enables adjustment of the number of turns without changing the entire winding pattern or manufacturing process, thereby resolving the contradiction between adaptability and manufacturing complexity.
2Power
If the axial length of the stator is varied to produce motors for different power classes, then motor power output is adjusted, but the number of turns must remain constant to maintain electrical boundary conditions
Solution Approach 1:
The patent applies parameter changes by modifying the jump width parameters of conductor clamps in at least two conductor clamp groups. By varying these geometric parameters, the number of turns in the winding can be adjusted independently of the stator's axial length. This allows motors of different power classes (with different axial lengths) to maintain compatible electrical boundary conditions through adjusted turn counts, resolving the contradiction between power adaptability and electrical boundary condition compatibility.
Data Source
Figure 1~2
Figure 3~5
AI summary
Described is a stator for an electrical machine (30) having a stator body (2) and an applied hairpin winding (5) having conductors (32) for a plurality of phases (6), wherein: a respective pole (22, 23, 27, 28) of the respective phase (6) is formed by a plurality of groove portion groups (20, 21) which each comprise groove portions (15, 16) which are arranged in a groove group (18, 19) of adjacent grooves (4) in the same layer of the hairpin winding (5); conductor clips (9 – 12) which form the groove portions (15, 16) of the respective groove portion group (20, 21) form a conductor clip group which connects adjacent poles (22, 23, 27, 28) of the respective phase (6); between the groove portions (15, 16) of the respective conductor clips (9 – 12) there are, in the circumferential direction, a number of skipped grooves (4) which are specified by a skip width (24 – 26) defined by the clip shape of the respective conductor clips (9 – 12); at least two of the conductor clip groups of the respective phase (6) have a different variation or combination of the skip widths (24, 25, 26) of the conductor clips (9 – 12) of the respective conductor clip group.