Electric Motor Stator Winding Layout for Parallel Coil Winding
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Solution Overview
Problem
Existing power tool electric motors with windings wound on a stator face inefficiencies in winding configurations, leading to uneven slot fill and increased material costs due to series configurations, which hinder throughput and require manual winding processes.
Innovation Solution
Implementing a parallel delta configuration for windings in the stator assembly, where each winding connects pairs of opposite coils in parallel, with crossovers extending around the circumference to connect coils electrically, and using elongated terminals to reduce stack length and automate the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If series configuration of windings is used, then manufacturing simplicity is maintained, but productivity decreases and material costs increase
Solution Approach 1:
The winding configuration is segmented into multiple independent parallel paths (first parallel path with first and second windings, second parallel path with third and fourth windings). This segmentation allows automatic winding machines to wind multiple coils simultaneously through different paths, significantly increasing productivity while maintaining manufacturing feasibility through standardized winding patterns in each path.
Solution Approach 2:
Multiple winding paths are merged into a single stator assembly with coordinated terminals. The parallel configuration merges the electrical paths such that current can flow through multiple windings simultaneously, achieving both high productivity (through parallel winding capability) and efficient current distribution across the motor windings.
2Loss of substance
If series configuration of windings is used, then device simplicity is maintained, but material costs increase
Solution Approach 1:
The winding system is divided into parallel paths with multiple windings in each path. This segmentation enables more efficient use of conductor material by allowing current to distribute across multiple parallel paths, reducing the total amount of copper or other conductive material needed compared to a series configuration where the same current must flow through all windings sequentially.
Solution Approach 2:
The electrical configuration parameters are changed from series to parallel connection. This parameter change fundamentally alters the current and voltage distribution characteristics, enabling material cost reduction through more efficient current distribution and reduced total conductor length requirements, while the standardized parallel path structure maintains manufacturing simplicity.
3Productivity
If manual winding process is used, then manufacturing precision can be maintained, but productivity decreases
Solution Approach 1:
The winding configuration is segmented into multiple standardized parallel paths with consistent winding patterns. This segmentation enables automatic winding machines to replicate identical winding sequences across different paths, achieving both high productivity through automation and uniform slot fill through standardized patterns that ensure consistent material distribution in each slot.
Solution Approach 2:
The parallel winding paths are designed with homogeneous structures - each path contains windings with identical turn counts, wire gauges, and winding patterns. This homogeneity ensures uniform slot fill across all slots even when using automatic winding equipment, as each path contributes equally and consistently to the overall winding uniformity, eliminating the productivity-precision trade-off.
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 configuration improves winding throughput, reduces material costs, and minimizes uneven slot fill by allowing automatic winding of multiple coils simultaneously, enhancing the efficiency and cost-effectiveness of the motor design.
Implementation Method 1
a stator assembly including a lamination stack and a printed circuit board assembly (PCBA) coupled to the lamination stack at an axial end of the stator assembly. The stator assembly also includes a plurality of windings wrapped about the lamination stack to form a plurality of coils
Data Source
AI summary
An electric motor includes a stator assembly including a lamination stack and a printed circuit board assembly (PCBA) coupled to the lamination stack at an axial end of the stator assembly. The stator assembly also includes a plurality of windings wrapped about the lamination stack to form a plurality of coils. The plurality of windings includes a first winding defining a first coil of the plurality of coils and a second coil of the plurality of coils located opposite from the first coil. The stator assembly further includes a plurality of terminals configured to electrically connect the plurality of windings to the PCBA. The plurality of terminals include a first terminal and a second terminal. The first coil and the second coil are connected in parallel between the first terminal the second terminal.