Semi-Staggered Motor Stator Winding Layout for Fewer Welds
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Solution Overview
Problem
The manufacturing process of motor stators is time-consuming due to the numerous welds required, and each weld is a potential source of resistive loss and failure, complicating the process with multiple coil types and epoxy application.
Innovation Solution
A semi-staggered winding layout with same-layer lead coils and complex twisting of weld pairs, such as reverse twisting and jumper weld pairs, reduces the number of unique coil types and concentrates all welds on one side, simplifying the manufacturing process and minimizing resistive losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional winding layouts with multiple coil types are used, then the motor stator can achieve proper electrical connections, but the manufacturing process becomes time-consuming and complex
Solution Approach 1:
The patent applies homogeneity by making all weld pairs identical in structure and configuration. Each weld pair consists of two conductors from the same layer welded together at the same location, eliminating the need for different coil types and complex welding patterns. This uniform approach simplifies manufacturing while maintaining electrical performance.
Solution Approach 2:
The weld pairs serve multiple functions: they provide electrical connections between coils, act as structural anchors for the windings, and enable phase connections. By making weld pairs universal and multi-functional, the patent eliminates the need for separate components and simplifies the overall winding structure.
2Reliability
If numerous welds are used to create proper electrical connections, then the motor stator achieves reliable electrical connectivity, but resistive losses and potential failure points increase
Solution Approach 1:
The patent extracts the welding operation from distributed locations throughout the stator and concentrates it at a single location (the crown end). This reduces the total number of welds required while maintaining all necessary electrical connections, thereby reducing resistive losses and potential failure points.
Solution Approach 2:
Multiple electrical connections are merged into single weld pairs. By having all conductors of the same layer weld together at the same location, the patent reduces the total number of weld joints while maintaining all necessary electrical pathways, thus minimizing cumulative resistive losses.
3Ease of manufacture
If welds are distributed on both sides of the stator stack, then proper electrical connections can be achieved, but the manufacturing process requires complex fixtures and multi-step epoxy application
Solution Approach 1:
The patent extracts all welding operations from the traditional distributed arrangement and relocates them to a single location at the crown end. This consolidation eliminates the need for complex fixtures and multi-step epoxy application, while maintaining all necessary electrical connections through the semi-staggered winding layout.
4Device complexity
If complex twisting patterns are applied to weld pairs, then the number of unique coil types is minimized, but the winding layout becomes more complex to implement
Solution Approach 1:
The patent changes the parameters of the winding layout by introducing semi-staggered positioning and complex twisting patterns. These parameter changes reduce the number of unique coil types to just three, simplifying the overall device complexity while the systematic approach to implementation maintains ease of manufacture.
Data Source
AI summary
A motor stator for a motor is disclosed. The motor stator includes a stator body and a plurality of windings. The stator body includes a weld end, a crown end, and a plurality of slots arranged circumferentially and extending axially therethrough between the weld end and the crown end, the slots including a plurality of layers arranged in a radial direction with layers being organized in conductor pairs. Each winding includes a plurality of coils and a plurality of weld pairs. Each weld pair includes legs of two respective coils joined together to form an electrical connection between the two respective coils. The plurality of weld pairs includes one or more jumper weld pairs arranged to jump the respective winding between two respective conductor pairs.