Segmented Electric Machine Active Parts with End-Face Winding Connections
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Solution Overview
Problem
Large electric motors and generators with segmented laminated cores face challenges in winding technology, including the inability to use two-layer windings, complex coil installation, and high costs and time for replacing defective segments, especially when using folding coil two-layer windings or single-layer windings with large coil dimensions.
Innovation Solution
The design of an electrical machine with segmented active parts featuring a single winding divided into sections, where each section has slots for winding segments with connection elements that can be easily connected and insulated, allowing for efficient assembly and replacement of segments, and enabling a more compact machine design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If segmented laminated cores are used in large electric motors or generators, then processability and transportability are improved, but the ability to use two-layer windings is lost and coil installation becomes complex
Solution Approach 1:
The stator is divided into multiple stator segments that can be manufactured and transported separately. Each segment contains slots for receiving coil sections, enabling modular assembly while maintaining the benefits of segmentation for processability and transportability.
Solution Approach 2:
The patent introduces a new dimensional arrangement by positioning connection elements on the end faces of stator segments, perpendicular to the direction of movement. This allows coil sections from adjacent segments to be connected in a different spatial dimension, simplifying the overall coil installation process while maintaining segmentability.
2Quantity of substance
If folding coil two-layer windings are used with segmented cores, then winding density is improved, but coil installation and insulation become complex and replacement of defective segments becomes time-consuming and expensive
Solution Approach 1:
The winding system is segmented along with the stator, with each stator segment containing complete coil sections that can be independently installed and replaced. The connection elements on end faces enable straightforward electrical connections between segments, simplifying replacement operations.
Solution Approach 2:
Connection elements are pre-positioned on the end faces of stator segments during manufacturing. This preliminary arrangement of connection points eliminates the need for complex field insulation and connection work during installation or repair, making segment replacement straightforward and cost-effective.
3Device complexity
If single-layer windings are used instead of folding coil two-layer windings, then coil installation is simplified, but coil dimensions become very large and different coil shapes are required
Solution Approach 1:
The single-layer winding is divided into multiple coil sections distributed across different stator segments. This segmentation allows each individual coil to maintain compact, uniform dimensions while the overall winding achieves the required complexity through the arranged connection of multiple segments.
Solution Approach 2:
The patent utilizes the radial dimension by positioning connection elements on the end faces of stator segments. This allows coil sections to be connected in a radial arrangement, maintaining uniform coil shapes and compact dimensions while achieving the functional equivalence of more complex winding configurations through spatial arrangement.
Data Source
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AI summary
The invention relates to an electric machine (10) with a first active part (12) and a second active part (16). The second active part (16) is movable relative to the first active part (12) in the direction of movement. The first active part (12) comprises at least a first active part segment (22) and at least a second active part segment (24). Furthermore, the first active part (12) has at least one winding (14) comprising a first winding section (26) and a second winding section (28). The first active part segment (22) also has slots (30) in which the first winding section (26) is arranged. The second active part segment (24) also has slots (32) in which the second winding section (28) is arranged. The first winding section (26) has a first connection element (34) which is arranged on a first end face (48) of the first active part segment (22).The second winding section (28) also has a second connection element (40), which is arranged on a second end face (52) of the second active part segment (24). The first end face (48) of the first active part segment (22) and the second end face (52) of the second active part segment (24) are arranged adjacent to each other. The first connection element (34) and the second connection element (40) are arranged next to each other.