Segmented Hairpin Winding Connection Layout

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Solution Overview

Problem

Multi-set segmented hairpin windings in electric machines face challenges with increased crowding at the connection end, leading to potential short circuits and manufacturing defects, as well as space constraints in compact applications like hybrid electric vehicles.

Innovation Solution

The implementation of a winding arrangement using differently shaped hairpin conductors, where all leg ends are bent the same number of slots and connected at the opposing side, eliminating the need for additional connections and jumpers at the connection side, and utilizing various hairpin conductor types for phase and set connections on the insertion side.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional multi-set segmented hairpin windings are used with all connections at the connection side, then the winding arrangement is complete, but the connection side becomes significantly crowded with leg ends, welding points, and connection wires causing clearance reduction and potential short circuits

Engineering Contradiction:

Improvewinding arrangement completenessVSAvoidconnection side crowding

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention divides the connection locations into two segments: the insertion side and the connection side. By distributing different types of connections to different sides (U-turns and special connections at insertion side, adjacent leg end connections at connection side), the congestion at the connection side is reduced while maintaining complete winding connections.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention utilizes the dimensional space by moving certain connections (U-turn portions and special connections) from the connection side to the insertion side, effectively distributing the connection density across two different spatial locations (sides of the stator) rather than concentrating all connections at one location.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Adaptability or versatility

If additional jumpers and terminals are added for phase and neutral connections, then the winding functionality is enhanced, but the clearance required at the connection end of the stator increases

Engineering Contradiction:

Improvewinding functionalityVSAvoidclearance at connection end

Core Design Contradiction:

Adaptability or versatilityVSLength of stationary object

Solution Approach 1:

The invention extracts the U-turn portions and special connections (including phase and neutral connections) from the connection side and relocates them to the insertion side. This removes the space-consuming elements from the connection end, reducing the clearance required at that location while preserving all necessary winding functionalities.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of placing all connections at the conventional connection side, the invention inverts the arrangement by placing U-turns and special connections at the insertion side, which is the opposite of the traditional approach. This inversion reduces the clearance requirements at the connection end while maintaining all necessary electrical connections.

Inventive Principle:

Principle #13The other way round (Inversion)

3Area of stationary object

If leg ends are closely aligned at the connection side for efficient space utilization, then space is optimized, but the welding points and connection wires create crowding that leads to manufacturing defects

Engineering Contradiction:

Improvespace utilizationVSAvoidwelding quality

Core Design Contradiction:

Area of stationary objectVSManufacturing precision

Solution Approach 1:

The invention segments the connection locations so that adjacent leg end connections are made at the connection side while U-turns and special connections are made at the insertion side. This segmentation reduces the density of welding points and connection wires at the connection side, improving welding quality and reducing manufacturing defects while maintaining efficient space utilization.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS7622843B2Terminals and connections between multi-set segmented hairpin windings

Publication Date: 2009.11.24 BORGWARNER INC

AI summary

An electric machine is disclosed herein comprising a core with a plurality of slots, the core including an insertion side and an opposing side. A winding arrangement is provided in the plurality of slots of the core. The winding arrangement is comprised of a plurality of differently shaped hairpin conductors. Each of the plurality of differently shaped hairpin conductors includes at least one leg inserted into one of the plurality of slots, with a leg end of the at least one leg extending from the opposing side of the core. All the leg ends extending from the opposing side of the core are bent the same number of slots and connected to immediately adjacent leg ends at the opposing side of the core. Thus, all connections between the differently shaped hairpin conductors are provided at the opposing side of the core.