Inner Stator Electrical Machine With Inverted Winding
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Solution Overview
Problem
Electrical machines with inner stators for direct drive applications face issues of increased weight, electric resistance, and reduced power due to lower winding space factor and longer coil connections, leading to higher material consumption and heat abstraction challenges.
Innovation Solution
The design incorporates salient poles with externally wound bobbins isolated from the stator elements, reducing copper wire usage and electric resistance by optimizing the winding space factor and shortening coil connections, along with improved heat abstraction through a dynamic seal and cooling ribs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If three-phase winding is laid in slots with conventional wire laying through narrower opening, then the winding can be installed, but the electric resistance increases and the winding space factor decreases
Solution Approach 1:
Instead of laying wire through narrow slot openings from the outside, the patent inverts the approach by introducing wire ends through the end face of the stator core and winding the wire directly in the slots from the inside outward. This reversal of the winding direction eliminates the constraint of narrow slot openings and enables efficient wire placement with optimal winding space factor.
2Reliability
If wire is laid through narrower slot opening, then winding installation is possible, but the length of coils end connections increases
Solution Approach 1:
The patent reverses the conventional winding approach by introducing wire ends through the stator core end face and winding from the inside outward. This inversion allows the wire to follow a more direct path within the slots, significantly reducing the length of end connections compared to conventional outside-in winding methods.
3Ease of manufacture
If winding space factor of wires towards slot walls is decreased, then wire laying is simplified, but heat abstraction from wires to stator pack worsens
Solution Approach 1:
By inverting the winding direction and filling slots from the inside outward, the patent ensures that wires are packed tightly against the slot walls with optimal contact. This inside-out approach maximizes the winding space factor and improves thermal contact between wires and stator pack, enhancing heat abstraction efficiency.
4Strength
If electric grade sheet quantity for stator pack making is increased, then stator structure is more robust, but electrical machine power decreases
Solution Approach 1:
The patent changes the winding parameters by adopting an inside-out winding method with optimized wire placement, which increases the winding space factor. This parameter change allows for reduced electric grade sheet quantity while maintaining structural integrity, thereby increasing the active copper content and electrical machine power.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces material consumption and electrical losses, increasing machine power by 20% while lowering temperature and resistance, and simplifying the manufacturing process.
Implementation Method 1
Internal canals 12 for circulating cooling liquid are formed in the inner aluminum housing 4
Implementation Method 2
electrical machine with inner stator and with permanent magnet excitation in outer rotor
Implementation Method 3
outer rotor 8 with permanent magnets 9
Data Source
AI summary
It is designed for traction motors in motor-in-wheels, fans, and direct driving electric machines. The inner stator (1) consists of pole elements (13) comprising external periphery (14), core (15), part of yoke (16), externally wound bobbin (3). The pole elements (13) on inner aluminum housing (4) are stationary fit. In housing (4) on bearings in end bells outer rotor (8) carrying motor-in-wheel (6) or another operating mechanism is sustained. The inner housing (4) is a carrier of the electrical machine and the operating mechanism, laterally closing side plate-carrier of electronic control device.


