Rotating Electric Machine Parallel Winding Segmentation

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Solution Overview

Problem

The existing rotating electric machines with distributed windings face increased manufacturing costs and time due to the high number of end-to-end connections required when coils are divided based on turns count, leading to stress on copper wires and potential insulation degradation.

Innovation Solution

The rotating electric machine employs a stator core with parallelly connected windings divided into subsets based on conductor count, reducing the number of connection sites by half through parallel connections, allowing for reduced stress and improved insulation reliability during manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If coils are divided into two rows based on turns count, then the number of copper wires is reduced, but the number of end-to-end connections increases

Engineering Contradiction:
Improvenumber of copper wiresVSAvoidnumber of end-to-end connections
Core Design Contradiction:
Quantity of substanceVSDevice complexity

Solution Approach 1:

The patent divides the coil into two separate rows (first row and second row) based on turns count, with each row containing a specific number of turns. This segmentation allows the coil to be inserted in a divided manner, reducing the quantity of copper wires that need to be handled at once while maintaining the total wire count. The segmentation principle directly addresses the contradiction by breaking down the single complex coil insertion into two simpler row-based insertions.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Instead of series-connecting the two rows as conventionally done, the patent inverts the connection approach by parallel-connecting the first row coil and the second row coil. This inversion of the connection method (from series to parallel) reduces the number of end-to-end connections required, as the parallel connection allows both rows to be connected to the same terminals without requiring intermediate series connections between rows.

Inventive Principle:
Principle #13The other way round (Inversion)

2Ease of manufacture

If distributed winding is employed with divided coils, then manufacturing flexibility is improved, but the number of connection sites increases

Engineering Contradiction:
Improvemanufacturing flexibilityVSAvoidnumber of connection sites
Core Design Contradiction:
Ease of manufactureVSDevice complexity

Solution Approach 1:

The distributed winding is segmented into two distinct rows (first row and second row) with specific turn allocations. This segmentation provides manufacturing flexibility by allowing each row to be independently prepared and inserted, while the parallel connection approach ensures that the number of connection sites does not multiply, thus resolving the contradiction between manufacturing ease and device complexity.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent merges the connection points of the two rows by parallel-connecting them to the same terminals. Instead of creating separate series connection paths that would increase the number of connection sites, the parallel connection merges the electrical paths, allowing both rows to share common terminals and thereby reducing the total number of connection sites required.

Inventive Principle:
Principle #5Merging (Combining)

3Ease of operation

If more end-to-end connections are made, then coil insertion flexibility is improved, but manufacturing cost increases

Engineering Contradiction:
Improvecoil insertion flexibilityVSAvoidmanufacturing cost
Core Design Contradiction:
Ease of operationVSEase of manufacture

Solution Approach 1:

The patent inverts the conventional series connection approach and adopts parallel connection for the two rows. This inversion reduces the number of end-to-end connections required, as parallel connections allow both rows to be connected to the same terminals without requiring multiple intermediate connection points. This directly reduces manufacturing cost while maintaining coil insertion flexibility through the divided row structure.

Inventive Principle:
Principle #13The other way round (Inversion)

Data Source

PatentUS10411530B2Rotating electric machine
Publication Date: 2019.09.10 KK TOSHIBA
  • US10411530B2 patent drawing
  • US10411530B2 patent drawing
  • US10411530B2 patent drawing

AI summary

A rotating electric machine of one embodiment includes a stator provided with a stator core having windings of each pole of each phase lap wound thereto; and a rotor provided rotatably with respect to the stator. The stator core is provided with slots each having two or more parallelly connected windings of equal turns count inserted therein.