Intertwined Wave Winding for Uniform Stator Thickness
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Solution Overview
Problem
Existing methods for producing distributed wave windings in electrical machines result in irregular thickness and torsional stress, leading to non-uniform wire course and thickness issues, especially when multiple layers are formed, making it difficult to achieve a coherent and uniformly interlaced winding with minimal thickness in stator or rotor head portions.
Innovation Solution
A method involving the simultaneous creation of interlaced wire groups on a rotatable striplike former, where straight segments and head portions are formed with controlled bending to ensure uniform alignment, allowing the wire groups to be intertwined and inserted as a coherent wave winding into slots, maintaining minimal thickness and uniform orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two winding halves are pressed flat separately in one ply, then the winding wires can be assembled efficiently, but the thickness becomes non-uniform and three wires intersect at close spacing
Solution Approach 1:
The winding is divided into two separate wire groups (first and second wire groups) that are interlaced independently before being combined. This segmentation allows each group to be formed with controlled thickness while maintaining overall coherence when assembled together, resolving the thickness uniformity issue.
Solution Approach 2:
Different regions of the winding are treated differently: the straight segments are pressed flat for uniform thickness, while the head portions are allowed to protrude and intersect in a controlled manner. This local differentiation resolves the contradiction between manufacturing efficiency and thickness uniformity.
2Productivity
If multiple layers of interlaced wires are formed, then the winding can extend around the stator or rotor circumference, but irregularities must be incorporated at layer transitions making production more difficult
Solution Approach 1:
The wire groups are pre-formed and interlaced in a controlled manner before assembly, with the head portions positioned to naturally transition between layers. This preliminary preparation eliminates irregularities at layer transitions and simplifies the overall production process.
3Manufacturing precision
If head portions are allowed to protrude from opposite ends of slots, then wire alignment can be improved, but the structure becomes more complex
Solution Approach 1:
The head portions of wires from opposite ends of slots are merged and joined together to form continuous conductive paths. This merging simplifies the overall structure by eliminating the need for separate connections while maintaining precise wire alignment through the interlacing pattern.
Data Source
AI summary
The disclosed stator or rotor has a distributed wave winding, in which the wires are associated in pairs lying with straight segments in the same slots. Head portions of two successive straight segments of each wire of a pair protrude from opposite ends of slots. For forming two wire groups, a plurality of coil windings are simultaneously created by winding up n parallel wires with intermediate spacing onto a striplike former that is rotatable about its longitudinal axis. From each of the parallel wires one straight segment and one end turn are doubled by being bent over with the wire length of a head portion, and then head portions are formed and the wires interlaced. Finally, the two wire groups are wound onto one another and thereby intertwined with one another, and then introduced as an entire intertwined wave winding strand into the stator or rotor slots.