Rotor and Stator Winding via Partial Phase Insertions
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Solution Overview
Problem
Conventional winding methods for rotors and stators in electrical machines result in suboptimal filling rates of notches, leading to reduced performance due to interference between phase windings, limiting the maximum filling rate to around 52% for three-phase and 50% for six-phase applications.
Innovation Solution
A method involving successive partial insertions of phase windings into notches, where each partial insertion is carried out for a part of the winding with fewer turns or wires than the complete configuration, allowing each partial insertion of a phase winding to be completed before moving on to the next, thereby reducing wire interference and enabling higher filling rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional winding methods are used with complete phase windings inserted sequentially, then the winding process is straightforward, but the filling rate of slots is limited to maximum 52% for three-phase and 50% for six-phase applications
Solution Approach 1:
The phase windings are divided into multiple partial insertions, where each insertion contains only a portion of the total turns (e.g., first insertion has N1 turns, second insertion has N2 turns, where N1 + N2 = total turns). This segmentation allows wires to be inserted in stages, reducing interference between phases and enabling higher filling rates of up to 55% for three-phase and six-phase applications.
2Manufacturing precision
If phase windings are inserted sequentially with complete windings, then the process is simple, but wire interference between phases increases and slot filling is suboptimal
Solution Approach 1:
The method performs preliminary partial insertions of phase windings before completing all insertions. The first partial insertion places initial turns that establish a foundation, and subsequent partial insertions add remaining turns. This preliminary action approach allows optimization of wire arrangement and achieves superior slot filling coefficients compared to conventional single-step insertion.
3Productivity
If complete phase windings are inserted at once, then the winding process is fast, but the insulation of wires experiences high stress
Solution Approach 1:
The winding process is segmented into multiple partial insertions rather than one complete insertion. Each partial insertion handles fewer turns, reducing the stress on wire insulation during the insertion process. This segmentation maintains productivity by systematically completing all phases while protecting wire integrity through reduced per-insertion stress.
4Ease of manufacture
If sequential complete phase windings are used, then the process is straightforward, but phase resistance is higher due to suboptimal filling
Solution Approach 1:
The method uses partial insertions that may initially appear excessive in number but ultimately achieve optimal filling. By performing multiple partial insertions rather than fewer complete ones, the method achieves superior slot filling coefficients that reduce phase resistance and energy losses, while maintaining manufacturing simplicity through systematic repetition of the partial insertion process.
Data Source
Figure 1~2
Figure 3a~3c
Figure 3d~3f
AI summary
The invention relates mainly to a method for winding a rotor or a stator (1) comprising K phase windings (E1-E3) each consisting of MxN corrugated conductors, M being the number of wires and N being the number of turns. According to the invention, the method comprises the step of consecutively performing, one after the other, partial insertions (E1a-E3a, E1b-E3b) of each phase winding (E1-E3) in a corresponding series of notches (S1-S3), each partial insertion (E1a-E3a, E1b-E3b) being performed for a portion of a phase winding having a number N of turns each consisting of a number of wires lower than M, or for a portion of a phase winding (E1-EK) having a number of turns lower than N each consisting of a number of wires equal to M. In addition, a partial insertion (E1a-E3a) of a given rank (j) is performed for all the phase windings (E1-E3) prior to passing to the partial insertion (E1b-E3b) of the subsequent rank (j+1) such that each partial insertion of a phase winding (E1-E3), except for that of the last rank, is performed before the windings of the other phases have been fully performed.