Segment Coil Layout for Equal-Height Rotary Electric Machine Windings
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Solution Overview
Problem
The existing rotary electric machines face challenges in manufacturing coil segments with different slot pitches due to varying bending angles and heights, leading to complex winding processes and reduced bending accuracy.
Innovation Solution
A rotary electric machine design with segment conductors having equal bending angles and aligned heights, where the first segment conductor is inserted at a first slot pitch and the second segment conductor at a smaller second slot pitch, ensuring equal protruding heights from the stator core, facilitating accurate positioning and bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bending angles are kept the same for segment conductors with different slot pitches, then inspection complexity increases, but manufacturing consistency is improved
Solution Approach 1:
The patent changes the geometric parameters of the segment conductors by introducing different slot pitches (first slot pitch and second slot pitch smaller than the first) while maintaining consistent bending angles. This parameter variation allows the same bending process to be applied to different conductor types, improving manufacturing consistency without increasing inspection complexity
2Adaptability or versatility
If segment conductors have different heights to accommodate different slot pitches, then slot pitch requirements are met, but winding process complexity increases
Solution Approach 1:
The patent applies local quality by making the linear portions of segment conductors have different lengths depending on their specific slot pitch requirements, while keeping the overall protruding height from the stator core end surface consistent. This localized variation in linear portion length allows different slot pitches to be accommodated without increasing winding process complexity
3Adaptability or versatility
If segment conductors have different protruding heights, then different slot pitches are accommodated, but bending accuracy decreases
Solution Approach 1:
The patent creates equipotentiality in the vertical dimension by ensuring that all segment conductors, regardless of their slot pitch or linear portion length, have the same protruding height from the stator core end surface. This uniform height level provides a consistent reference plane that improves bending accuracy while still accommodating different slot pitches through variations in linear portion lengths
Data Source
AI summary
An object of the present invention is to provide a rotary electric machine capable of reducing a difference between a height of a first segment conductor and a height of a second segment conductor. A first segment conductor 121 having a first slot pitch and a second segment conductor 122 having a second slot pitch smaller than the first slot pitch are provided, the second segment conductor 122 includes a first leg portion 122A and a second leg portion 122B, the first leg portion 122A includes a slot insertion portion 122A0 and a first linear portion 122A2 connected to the slot insertion portion 122A0 and constituting a coil end portion, the second leg portion 122B includes a slot insertion portion 122B0 and a second linear portion 122B2 connected to the slot insertion portion 122B0 and constituting a coil end portion, and the second linear portion 122B2 is longer than the first linear portion 122A2.