Pre-wound Stator Teeth for High Slot Fill
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Solution Overview
Problem
Traditional stator designs with integral teeth limit the cross-sectional area of coil windings, leading to inefficiencies in thermal conductivity and motor performance, and require complex winding processes, while existing solutions for separate stator teeth complicate the manufacturing of multiphase electric motors.
Innovation Solution
The design allows stator teeth to be pre-wound independently and then mounted to a stator back-iron, maximizing coil winding cross-sectional area and simplifying the mounting process, using separate teeth with recesses and protrusions for secure engagement and improved thermal conductivity through over-moulding with insulating materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the stator is formed as a single solid piece with integral teeth, then the structural strength and simplicity of assembly are improved, but the cross-sectional area of coil windings is limited and gaps form between coils of adjacent teeth
Solution Approach 1:
The stator is divided into separate components: a back-iron and individual stator teeth that are mounted separately. This segmentation allows each tooth to be independently wound with coils, eliminating gaps between coils of adjacent teeth and maximizing the cross-sectional area of coil windings while maintaining structural integrity through the back-iron connection.
2Reliability
If traditional coil insulation is used between stator and coil windings, then electrical insulation is provided, but thermal conductivity is poor which limits motor performance
Solution Approach 1:
A composite material is used for coil insulation that combines both electrical insulation properties and high thermal conductivity. This composite material allows heat to be efficiently conducted away from the coil windings while maintaining the necessary electrical insulation, thereby improving motor performance and reducing energy loss.
3Ease of manufacture
If separate stator teeth are used for simplified winding, then the winding process is simplified, but the mounting process becomes complicated for multiphase electric motors
Solution Approach 1:
The stator teeth are designed with universal mounting features that allow them to be mounted to the back-iron in a standardized manner regardless of the specific multiphase configuration. This universal design simplifies the mounting process by providing consistent engagement mechanisms while still allowing flexibility for different winding configurations.
4Area of stationary object
If stator teeth are placed in a position optimized for coil winding, then the cross-sectional area of coil windings is maximized, but the mounting position may not be optimized
Solution Approach 1:
The stator teeth are pre-positioned on the back-iron in the optimal configuration for coil winding before the actual winding process begins. This preliminary positioning ensures that the teeth are in the correct orientation and location to maximize the cross-sectional area of coil windings, while the modular design allows for easy adjustment and optimization of the mounting process.
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 increases the slot fill percentage of coil windings to 54% or more, enhances thermal conductivity, and simplifies the winding and mounting processes, leading to improved motor efficiency and performance.
Implementation Method 1
the protrusions are arranged to engage with recesses in the stator tooth and provide a thermal conduction path between the coil winding and the stator back iron
Implementation Method 2
Electric motors work on the principle that a current carrying wire will experience a force in the presence of a magnetic field
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
An arrangement for mounting a coil winding on a stator tooth, the arrangement comprising a mounting element having a first mounting arm for receiving a first stator tooth and a second mounting arm for receiving a second stator tooth, wherein the first mounting arm is movable relative to the second mounting arm between a first position and a second position; means for mounting an electrical conductor on the first stator tooth and the second stator tooth when the first mounting arm is in the first position relative to the second mounting arm to form a coil winding on the first stator tooth and the second stator tooth; and means for placing the first mounting arm in the second position relative to the second mounting arm when the conductor has been mounted on the first stator tooth and the second stator tooth to allow the first stator tooth and the second stator tooth to be removed from the first mounting arm and the second mounting arm respectively.