Parallel Winding Slots for Stator Coil Insertion
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Solution Overview
Problem
The existing method of forming single-layer stator windings in rotating electrical machines is time-consuming and requires high skill due to the need for pre-formed coils to be angled relative to each other for insertion into radial slots, which can lead to damage and is particularly challenging in large machines with high numbers of poles.
Innovation Solution
The stator design features parallel winding slots formed by rotating conventional radial slots, allowing pre-formed coils to be inserted with axially-extending winding runs that are parallel to each other, reducing the complexity and risk of damage during the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pre-formed coils are inserted into radial slots with winding runs angled relative to each other, then the coils can be received in winding slots that are separated by intermediate winding slots, but the winding process becomes time-consuming and requires high skill due to the difficulty of positioning angled coils
Solution Approach 1:
The patent applies asymmetry by intentionally angling the winding slots relative to the radial direction. Instead of using conventional radial slots where coils must be positioned at specific angles, the slots are formed at an angle θ to the radius, which allows the winding runs to be substantially parallel and simplifies the insertion process while maintaining the required coil geometry for electrical machine operation
Solution Approach 2:
The patent changes the geometric parameter of the winding slots from radial (0° angle to radius) to angled (θ ≠ 0° angle to radius). This parameter change transforms the insertion difficulty from handling angled coils in radial slots to handling parallel coils in angled slots, significantly improving ease of operation and reducing winding time
2Reliability
If pre-formed coils are inserted with winding runs angled relative to each other, then the coils can be properly received in radial winding slots, but the risk of coil damage increases during the winding process
Solution Approach 1:
The patent uses asymmetry by forming winding slots at an angle θ to the radius rather than strictly radial. This asymmetric configuration allows coils to be inserted with parallel winding runs, eliminating the need to manipulate and position angled coils, thereby reducing handling complexity and minimizing the risk of coil damage during insertion
Solution Approach 2:
By changing the slot angle parameter from radial (0°) to angled (θ), the patent transforms the insertion process from a high-risk operation involving angled coil positioning to a low-risk operation with parallel coil insertion, significantly improving coil integrity while maintaining electrical performance
3Productivity
If conventional radial slots are used, then the stator teeth characteristics are optimized and structural strength is maximized, but the winding process becomes complex and time-consuming
Solution Approach 1:
The patent applies asymmetry by deviating from conventional radial slot configuration and forming slots at an angle θ to the radius. This asymmetric design simplifies the winding process and reduces complexity by allowing parallel coil insertion, while the slot geometry is carefully designed to maintain adequate stator tooth characteristics and structural strength
Solution Approach 2:
The patent changes the critical geometric parameter of the winding slots from radial orientation to angled orientation (θ ≠ 0°). This parameter change fundamentally simplifies the winding process and reduces operational complexity, while the specific angle θ is selected to balance the trade-off between winding ease and stator tooth performance
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention provides an improved stator (28) for rotating electrical machines with single-layer stator windings consisting of a plurality of pre-formed coils (22) of equal angular pitch. The stator (28) has a first cylindrical surface in which a plurality of circumferentially spaced winding slots (30) are formed and in which the axially- extending winding runs (24) of the pre-formed coils (22) are positioned. The two winding runs (24) of each coil (22) will each be positioned in a winding slot (30) and the two winding slots (30) that receive the coil (22) define a winding slot pair. The improvement arises from the fact that the winding slots (30) of each winding slot pair extend into the stator (28) in substantially parallel directions. This means that the axially-extending winding runs (24) of each pre-formed coil (22) may also be substantially parallel and need not be angled towards each other. This enables the stator (28) to be easily wound as each pre-formed coil (22) may be simply and easily slotted into a parallel winding slot pair.