Multi-tiered Stator End Turns for Compact Electric Machines
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Solution Overview
Problem
Existing electric machine designs face challenges in achieving a compact and efficient structure with reduced size and increased efficiency while maintaining cost-effective manufacturing, particularly in vehicle applications, due to varying end turn heights and complex manufacturing processes.
Innovation Solution
A multi-phase electric machine with a stator featuring windings of equal linear length, arranged in multiple wraps and layers, where each wrap circumscribes the stator core, allowing for precise end turn formation and simplified manufacturing by using equal-length winding wires, reducing the maximum wire end height and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If windings of different lengths are used to achieve equal end turn heights, then the end turn height uniformity is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent introduces a transition layer between outer and inner layers, where windings in the transition layer have different lengths than windings in the outer or inner layers. This local differentiation allows end turns in the transition layer to extend to a different axial position, creating a stepped configuration that equalizes maximum end turn heights across all layers while maintaining manufacturing feasibility through standardized winding lengths for each layer type.
2Manufacturing precision
If windings of different lengths are used to achieve equal end turn heights, then the end turn height uniformity is improved, but the manufacturing cost increases
Solution Approach 1:
The patent introduces a transition layer between outer and inner layers, where windings in the transition layer have different lengths than windings in the outer or inner layers. This local differentiation allows end turns in the transition layer to extend to a different axial position, creating a stepped configuration that equalizes maximum end turn heights across all layers while maintaining manufacturing feasibility through standardized winding lengths for each layer type.
3Volume of moving object
If the electric machine size is reduced, then the compactness is improved, but the efficiency may be compromised
Solution Approach 1:
The patent utilizes the axial dimension by creating a multi-tiered end turn configuration with outer, transition, and inner layers at different axial positions. This vertical arrangement allows the stator to achieve a compact radial footprint while maintaining sufficient winding length and turn count for high efficiency through the axial stacking of winding layers.
Data Source
AI summary
An electric machine having a stator with windings all having the same length. The stator includes a plurality of slots. A plurality of windings are mounted in the slots of the stator core and define a plurality of poles circumferentially distributed about the stator core. Each winding defines at least a first wrap and a second wrap wherein each of the first and second wraps circumscribes the stator core. Each of the first and second wraps includes a wire segment disposed in a slot in each pole. The first wrap of each winding is primarily disposed in one of the layers and the second wrap of each winding is primarily disposed in a different one of the layers. The first wrap of each winding defines a first linear length and the second wrap of each winding defines a second linear length that differs from the first linear length.