Hairpin Winding Electric Machine Double-Layer Stator Design
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Solution Overview
Problem
Hairpin winding technology in electric machines faces challenges in creating double-layer windings due to complex hairpin formations, increased cost, and reduced compactness, limiting options for conductor connections and torque-speed curve matching.
Innovation Solution
A unique connection arrangement using selectively pitched hairpins with minimal geometry modifications allows for the formation of double-layer windings without additional jumpers or welding, maintaining simplicity in hairpin geometry and avoiding sharp bending, enabling efficient torque ripple and noise reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional hairpin winding methods are used to create double-layer windings, then winding complexity increases, but manufacturing cost increases and compactness decreases
Solution Approach 1:
Instead of modifying hairpin geometry to achieve double-layer windings, the patent inverts the approach by maintaining standard hairpin geometry and using a unique connection arrangement where hairpins are interconnected through slot regions. This allows double-layer winding configuration without complex hairpin formations or additional jumpers.
Solution Approach 2:
The patent utilizes the radial dimension within stator slots to accommodate multiple hairpin connections. By arranging hairpin connections in radial layers within slot regions, the patent achieves double-layer winding configuration without increasing circumferential complexity or requiring additional stator slots.
2Adaptability or versatility
If traditional hairpin winding methods are used to create double-layer windings, then winding complexity increases, but manufacturing cost increases
Solution Approach 1:
Instead of modifying hairpin geometry to achieve double-layer windings, the patent inverts the approach by maintaining standard hairpin geometry and using a unique connection arrangement where hairpins are interconnected through slot regions. This allows double-layer winding configuration without complex hairpin formations or additional jumpers.
Solution Approach 2:
The patent extracts the connection function from traditional jumper elements and integrates it directly into the hairpin interconnection structure within slot regions. This eliminates the need for additional jumpers and reduces manufacturing steps while maintaining electrical connectivity for double-layer windings.
3Adaptability or versatility
If additional jumpers or welding are used for hairpin connections, then connection flexibility increases, but device complexity increases
Solution Approach 1:
The patent merges the hairpin conductor and connection structure into a unified arrangement where hairpins are directly interconnected through slot regions. This eliminates separate jumpers and integrates connection functionality into the hairpin structure itself, reducing overall device complexity while maintaining connection flexibility.
Solution Approach 2:
The hairpin structure serves multiple functions simultaneously: it provides electrical conductivity, structural support, and interconnection between phases. The unique connection arrangement allows the same hairpin structure to fulfill multiple roles without requiring additional specialized components.
4Productivity
If more coils are added to improve torque-speed curve matching, then performance improves, but stator slot capacity is exceeded
Solution Approach 1:
The patent utilizes the radial dimension within stator slots to accommodate multiple hairpin connections. By arranging hairpin connections in radial layers within slot regions, the patent achieves double-layer winding configuration without increasing circumferential complexity or requiring additional stator slots.
Solution Approach 2:
The patent nests multiple hairpin connections within the same stator slot by utilizing radial layers. Hairpins are arranged in nested configurations where inner and outer radial layers coexist within slot regions, effectively increasing coil capacity without expanding stator slot physical dimensions.
Data Source
AI summary
An electric machine includes a stator core defining circumferentially-arranged slots each having radial pin positions arranged to define radial layers and a hairpin winding including a first path of interconnected hairpins disposed in the stator core. The hairpins are arranged such that a leg portion of each hairpin is routed through a radial pin position of each slot wherein at least one uniquely-pitched hairpin is provided along the first path to induce a first shift in a trailing portion of the first path.