Motor Stator Segmentation for Automated Winding
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Solution Overview
Problem
The complexity of winding and connection processes in stators with 12 salient poles and 10-pole-magnetized rotors complicates automation, increases manufacturing costs, and reduces the space factor and efficiency of windings due to the need for thick wires and complicated wire connections.
Innovation Solution
A motor design with 12 core pieces having concentrated windings wound in the same direction, connected via a 3-phase-Y-connection through a wiring board, where adjacent same-phase windings have opposite current directions and adjacent different-phase windings have the same current directions, allowing for efficient and automated manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If concentrated windings are wound in different directions to create unlike poles, then the motor can generate torque, but the winding and connection processes become very complicated
Solution Approach 1:
The stator is divided into 12 separate core pieces, each with its own concentrated winding. This segmentation allows each core piece to be wound independently in the same direction, simplifying the winding process while still achieving the required magnetic pole configuration through the combination of core pieces and wiring board connections
Solution Approach 2:
A wiring board is introduced as an intermediary component to manage the connections between the 12 core pieces. The wiring board provides standardized connection points that simplify the complex interconnections required to create the 3-phase-Y-connection pattern, replacing direct complex wire-to-wire connections with a structured intermediary layer
2Power
If thick wires are used to maintain high output with continuous winding, then the motor output is maintained, but the space factor of the slot decreases
Solution Approach 1:
The winding system is segmented into 12 separate core pieces with concentrated windings, allowing the use of thinner wires that can be more efficiently packed into slots. This segmentation enables better space utilization while maintaining the required current carrying capacity through the distributed winding configuration
Solution Approach 2:
The wire diameter parameter is optimized by using thinner wires in the concentrated windings of each core piece. The overall motor output is maintained not by individual wire thickness but by the combined effect of multiple windings connected in the 3-phase-Y-connection pattern through the wiring board
3Ease of manufacture
If the same phase windings are connected in series only, then the connection process is simplified, but the space factor of the slot deteriorates due to thick wire requirements
Solution Approach 1:
The wiring board serves as an intermediary that implements the 3-phase-Y-connection pattern, providing a structured method to connect same-phase windings in series while connecting adjacent different-phase windings in parallel. This intermediary structure achieves both simplified connection processing and improved space factor through optimized wire routing and connection points
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 design results in a high-output motor with a high space factor in the winding slots and reduced cogging torque, enabling efficient manufacturing and cost-effectiveness while maintaining high performance and low noise.
Implementation Method 1
a first winding, which is arranged at a position of 180° of the mechanical angle, and a second winding of the same phase are arranged being wound in different directions so that they can be unlike poles from each other
Implementation Method 2
a 10-pole-magnetized rotor and a stator having 12 salient poles and windings wound round the salient poles
Data Source
AI summary
A motor includes: a rotor in which 10 poles are magnetized at regular intervals; a stator having 12 core pieces and facing the rotor, all core pieces having a concentrated winding wound in the same direction and being annularly arranged; and a wiring board for making 3-phase connection of the windings. A wire connection is made through the wiring board in such a manner that electric currents of adjacent same phase windings flow in opposite directions and of electric currents of adjacent different phase windings flow in same directions.