Multi-Phase Stator Assembly for Easier Electric Drive Manufacturing
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Solution Overview
Problem
The manufacturing of high-phase stators for electric drives is inefficient due to the time-consuming and error-prone process of accurately positioning electrically conductive rods in slots, leading to increased costs and complexity.
Innovation Solution
The electric drive design incorporates multiple conductor sections connected to separate short-circuiting means, allowing for efficient insertion and insulation of conductor sections, reducing the number of connections per short-circuiting means, and enabling flexible design and operation with adjustable phase currents to generate rotating fields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of electrical phases of the stator is increased, then the power and performance of the electric drive are improved, but the manufacturing cost and complexity of the stator are substantially increased
Solution Approach 1:
The stator is divided into multiple independent modules, each containing a subset of conductor sections connected to a common short-circuiting means. This segmentation allows the complex multi-phase stator to be manufactured as separate, simpler modules that are subsequently assembled, reducing the overall manufacturing complexity while maintaining high power capability through the combined effect of all phases.
2Power
If the number of electrical phases of the stator is increased, then the power and performance of the electric drive are improved, but the time required to position rods accurately in slots is substantially increased
Solution Approach 1:
Conductor sections are pre-assembled into modular groups with their associated short-circuiting means before insertion into the stator slots. This preliminary assembly reduces the complexity of on-site positioning during final stator assembly, as each module is a self-contained unit that requires less precise individual rod positioning compared to assembling all conductor sections separately.
3Ease of manufacture
If conductor sections are divided into multiple groups with separate short-circuiting means, then the manufacturing process is simplified and errors are reduced, but the number of components and connections is increased
Solution Approach 1:
Multiple conductor sections that would otherwise require individual short-circuiting connections are merged into groups, with each group sharing a common short-circuiting means. This merging reduces the total number of short-circuiting components needed compared to treating each conductor section independently, while still providing the manufacturing simplicity benefits of modular assembly.
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 approach simplifies the manufacturing process, reduces errors, and allows for efficient operation with adjustable conductor sections, enhancing the stator's design flexibility and reducing installation space requirements.
Implementation Method 1
The first and second conductor sections are each designed to be supplied with a separate phase current... which can generate one or more rotating fields during operation of the electric drive
Data Source
AI summary
An electric drive (20) comprising an electric machine (10) is specified. The electric machine (10) comprises a stator (21) and a rotor (22) mounted so as to be movable with respect to the stator (21), wherein the stator (21) comprises at least two first conductor sections (23) and at least two second conductor sections (24), the stator (21) comprises at least one first short-circuiting means (25) and at least one second short-circuiting means (26), the first conductor sections (23) are electrically connected to the first short-circuiting means (25), the second conductor sections (24) are electrically connected to the second short-circuiting means (26), and the first conductor sections (23) and the second conductor sections (24) are each designed to be supplied with a separate electric phase. Moreover, a supply system (46) for the electric drive (20) and a method of operating the electric drive (20) are specified.