Offset-Pin Stator Winding Layout for Low Torque Ripple
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing stators for electric machines face challenges in efficient manufacturing and electromagnetic field generation, with current designs often resulting in torque ripples and poor NVH (Noise, Vibration, and Harshness) properties due to complex winding configurations.
Innovation Solution
A stator design featuring pins arranged on concentric circles with specific connection types across different layers, allowing for efficient winding formation and reduced harmonic disturbances, utilizing pre-bent double pins and single pins to create a symmetrical electromagnetic field with fewer torque fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If complex winding configurations are used in existing stators, then electromagnetic field generation capability is improved, but manufacturing efficiency deteriorates and torque ripples increase
Solution Approach 1:
The winding is divided into multiple discrete pins arranged in different layers (first layer with pins in first and second slots, second layer with pins in third and fourth slots, etc.), allowing independent placement and connection of each pin segment. This segmentation enables simplified manufacturing processes while maintaining the complete winding configuration for effective electromagnetic field generation.
2Power
If complex winding configurations are used in existing stators, then electromagnetic field generation capability is improved, but torque ripples and NVH properties deteriorate
Solution Approach 1:
The pin arrangement uses asymmetric slot positioning across different layers (first slot in outer layer, second slot in inner layer, third slot in outer layer, etc.) creating a non-uniform distribution pattern. This asymmetric configuration balances the electromagnetic forces more effectively, reducing torque ripples and improving NVH characteristics while maintaining strong electromagnetic field generation.
3Ease of manufacture
If pins are arranged in multiple layers with specific connection types, then manufacturing simplicity is improved, but winding configuration complexity increases
Solution Approach 1:
The pins are pre-positioned in specific slots during the winding formation process (first pin in first slot, second pin in second slot, third pin in third slot, etc.) before final assembly. This preliminary arrangement establishes the correct multi-layer configuration early in manufacturing, simplifying subsequent connection steps while ensuring the complex winding pattern is achieved without manual complexity.
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
The design simplifies manufacturing, reduces torque ripples and NVH issues, and enables a uniform rotating field with improved symmetry, allowing for efficient electromagnetic field generation and better performance in electric machines.
Implementation Method 1
A stator (1) for an electric machine with a plurality of pins (2, 3) which are arranged on concentric circles at different distances to a stator center in slots (5) in the stator
Implementation Method 2
The connection type may be a welding of conductors to the pins, or the pins may already be designed as double pins, so-called U pins, and thus already establish a connection upon insertion into the stator
Data Source
AI summary
A stator for an electric machine includes a plurality of pins arranged on concentric circles at different distances to a stator center in slots in the stator, and each concentric circle forms a layer. In each case, six pins in different layers are serially connected to one another and form a winding. A first pin of the winding is located in a first slot in the 6n-1 layer, wherein n is an integer. A second pin of the winding is located in a second slot in the 6n layer. A third pin of the winding is located in the first slot in the 6n-2 layer. A fourth pin of the winding is located in the second slot in the 6n-3 layer. A fifth pin is located in the first slot in the 6n-5 layer. A sixth pin of the winding is located in the second slot in the 6n-4 layer.