Hairpin Stator Winding Layout Without Bus Bars
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Solution Overview
Problem
The complexity and high production cost of electric motor stators due to the numerous bus strips and bus bars required for connecting hair-pin coils in existing technologies, which complicates manufacturing and reduces processing efficiency.
Innovation Solution
A stator winding design with fewer types of coil units and a simple arrangement mode, where hair-pin coils with different pitches are arranged in specific slots and layers, allowing direct phase connections without bus bars, enabling terminals and neutral points to be placed in any slot and layer, thereby simplifying manufacturing and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional hair-pin coil arrangements with multiple bus strips and bus bars are used, then the electrical connections between coils can be established, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent extracts and eliminates the bus strips and bus bars from the traditional hair-pin coil arrangement. By directly connecting the coil terminals to the slot, the intermediate connection components are removed, simplifying the overall structure while maintaining electrical connection reliability
Solution Approach 2:
The patent merges the coil terminal connection function directly into the slot structure. The coil terminal is inserted directly into the slot without requiring separate bus strips or bus bars, combining multiple functions into a single integrated arrangement
2Reliability
If traditional hair-pin coil arrangements with multiple bus strips and bus bars are used, then the electrical connections can be established, but the production cost increases
Solution Approach 1:
The patent removes the expensive bus strips and bus bars from the assembly, eliminating material costs and reducing overall production cost while maintaining necessary electrical connections through direct slot insertion
Solution Approach 2:
The patent replaces expensive, complex bus strip and bus bar assemblies with a simpler, more cost-effective direct insertion connection method that achieves the same electrical connection function at lower cost
3Reliability
If traditional hair-pin coil arrangements are used, then the coils can be connected, but the processing efficiency decreases due to complicated manufacturing techniques
Solution Approach 1:
By removing the bus strips and bus bars, the manufacturing process is simplified, eliminating complex assembly steps and improving processing efficiency while maintaining reliable electrical connections
Solution Approach 2:
The coil terminals are pre-formed with insertion structures that enable direct placement into slots, preparing the components in advance for simplified assembly and improving overall manufacturing efficiency
Data Source
AI summary
The present disclosure discloses an electric motor stator and an electric motor. The electric motor stator comprises: a stator core, the stator core being provided with a plurality of stator core slots, the plurality of stator core slots being formed on a radial inner surface of the stator core and being separated by a preset slot distance along a circumferential direction of the stator core; a stator winding, the stator winding being mounted on the stator core, the stator winding being provided with Q pole pair coils, wherein Q/a number of slots per pole per phase=P, P being an integer; wherein the stator winding being a three-phase winding, the number of slots per pole per phase being 3; the stator winding comprising: a first coil set and a third coil set successively sleeved from outside to inside.