Vehicle Motor Stator Coil Structure With Flat-Wire Step Profile
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Solution Overview
Problem
Conventional vehicle motors with round cross-sectional wires have a suboptimal coil space factor after multi-turn stacked winding, leading to inefficiencies in motor performance.
Innovation Solution
A vehicle motor stator structure utilizing a stator core assembly with an annular portion and tooth portions, where coil assemblies composed of flat wires with different cross-sectional thicknesses and widths are radially stacked and wound around the tooth portions, enhancing the coil space factor by forming a step profile and reducing power losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If round cross-sectional wires are used for stacking and winding around the teeth of the iron core, then the winding process can be simplified, but the coil space factor remains suboptimal and motor performance is limited
Solution Approach 1:
The patent changes the cross-sectional shape parameter of the wire from round to flat rectangular, and introduces different thickness specifications (first thickness for inner layer, second thickness for outer layer). This parameter change enables better space utilization in the winding groove while maintaining the stacked winding process simplicity, thereby resolving the contradiction between ease of manufacture and coil space factor.
Solution Approach 2:
The patent segments the coil assembly into multiple layers with different wire thicknesses - first flat wires with first thickness form the inner layer, and second flat wires with second thickness form the outer layer. This segmentation allows optimal filling of the winding groove space, improving coil space factor while keeping the manufacturing process straightforward.
2Productivity
If multi-turn stacked winding is performed to maximize coil space factor, then more wire can be packed, but the process time increases significantly
Solution Approach 1:
The patent prepares flat wires with predetermined thicknesses and dimensions before the winding process. The first flat wires and second flat wires are pre-manufactured with specific thicknesses optimized for their respective layers, eliminating the need for complex on-site adjustments during multi-turn stacked winding. This preliminary preparation maintains high coil space factor while reducing overall process time.
3Ease of manufacture
If uniform thickness wires are used for stacking, then the manufacturing process is simpler, but the coil space factor and motor performance are suboptimal
Solution Approach 1:
The patent applies different wire thicknesses at different locations within the coil assembly - first flat wires with first thickness are used in the inner layer closer to the tooth, while second flat wires with second thickness are used in the outer layer. This local differentiation optimizes the magnetic field distribution and improves motor performance while keeping the manufacturing process relatively simple through standardized production of different wire specifications.
Data Source
AI summary
A stator structure of a vehicle motor includes a stator core assembly and a plurality of coil assemblies composed of flat wires. The stator core assembly includes an annular portion and a plurality of tooth portions. The tooth portions extend from the annular portion in a radial direction toward a center of the stator core assembly. Each coil assembly is configured around a corresponding tooth portion. Each coil assembly includes a first flat wire and a plurality of second flat wires that are electrically connected in parallel. The first flat wire is radially stacked and wound around the corresponding tooth portion. The second flat wires are arranged radially adjacent to the first flat wire and are electrically connected in series to the first flat wire. The second flat wires are alternately stacked and radially wound around the corresponding tooth portion.