Side-by-Side Phase Winding Layout for Lower Inter-Phase Discharge
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Solution Overview
Problem
Conventional flat copper wire windings in motors suffer from low space utilization, high production costs, and reduced service life due to voltage differences between phase windings, leading to inter-phase discharge and complex hairpin conductor structures.
Innovation Solution
A side-by-side phase winding configuration using two coil ring groups with staggered hairpin conductors, where each coil ring consists of multiple hairpin conductor groups arranged in a staggered manner to minimize inter-phase conductor area and reduce voltage differences, thereby simplifying production and extending motor lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hairpin conductor structures are used to minimize voltage difference influence, then the service life is improved, but the device complexity and production cost increase
Solution Approach 1:
The patent applies homogeneity by making all hairpin conductors within the same phase winding identical in structure and arrangement. Specifically, all hairpin conductors have the same U-shaped configuration with support legs positioned at consistent intervals around the stator circumference, eliminating the need for multiple specialized conductor types while maintaining reliable voltage distribution and reducing production complexity
Solution Approach 2:
The patent merges multiple hairpin conductors into a unified phase winding structure where conductors from different phases are systematically arranged in the same stator slots. This integration allows for standardized conductor designs that serve multiple phases, reducing overall device complexity while maintaining service life through balanced voltage distribution
2Reliability
If multiple types of hairpin conductors are used to arrange support leg parts, then the voltage difference influence is reduced, but the manufacturing cost and assembly difficulty increase
Solution Approach 1:
The patent uses identical hairpin conductor structures for all phases, with each conductor having the same U-shaped form and support leg configuration. This homogeneous approach simplifies manufacturing by requiring only one type of conductor to be produced and assembled, while the systematic arrangement of these identical conductors in stator slots effectively mitigates voltage differences between phases
Solution Approach 2:
The patent segments the phase winding into multiple identical hairpin conductors that are distributed around the stator circumference. Each conductor is a discrete U-shaped unit with support legs, and these segmented identical units are arranged in a pattern that balances voltage distribution across phases, achieving both voltage difference mitigation and manufacturing simplicity
3Ease of manufacture
If round wires are used for winding, then the winding process is simple, but the space utilization and power density are low
Solution Approach 1:
The patent transitions from round wires to flat copper conductors with rectangular cross-sections. This shape change allows the conductors to be arranged more efficiently in the stator slots, increasing the quantity of copper that can be packed into the available space and thereby increasing power density, while the standardized hairpin structure maintains manufacturing simplicity
Data Source
AI summary
Disclosed are a side-by-side phase winding, a stator and a motor. The side-by-side phase winding comprises two coil ring groups each consisting of Q coil rings, each coil ring being formed by connecting in series P hairpin conductor groups uniformly distributed in the circumferential direction; each hairpin conductor group comprises two hairpin conductors which are arranged in a staggered manner in the circumferential direction of the stator, each hairpin conductor comprises a hairpin main body which is integrally bent into a U-shape, the hairpin main body comprises two leg parts, a head part and support feet, and adjacent leg parts on the two hairpin conductors arranged in a staggered manner are located in two adjacent slots; and the Q coil rings in each coil ring group are arranged in Q circumferentially continuous adjacent slots of the stator.