Segmented Stator Assembly for High Wire Density Winding
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Solution Overview
Problem
The power density and efficiency of electrical machines are limited by the accessibility of wire winding around stator teeth, which decreases with motor size and increasing number of teeth, making it difficult to achieve high wire density and torque while maintaining compact and lightweight designs.
Innovation Solution
A stator assembly composed of individual stator segments, where each segment may be shared between adjacent stators, allowing for increased wire winding density and torque output by optimizing the slot area and configuration, including asymmetrical and polygonal slot shapes, and varying tooth lengths and numbers to adjust torque characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a fully round, single piece stator is used, then the structure is simple and manufacturing is easier, but the accessibility of wire winding around each tooth decreases with motor size and increasing number of teeth, limiting power density and efficiency
Solution Approach 1:
The stator is divided into multiple stator segments that can be assembled together to form a complete stator. Each segment provides accessible slots for wire winding, and the segments are configured to create optimal winding access while maintaining the overall stator structure. This segmentation resolves the contradiction by enabling high wire density through improved accessibility without requiring a completely different manufacturing approach.
2Reliability
If the slot opening between adjacent teeth is reduced for electromagnetic reasons (reducing cogging torque), then electromagnetic performance improves, but access for winding through the slot opening becomes infeasible
Solution Approach 1:
By dividing the stator into segments, the design allows for optimized slot openings that provide both the electromagnetic performance benefits of reduced cogging torque and sufficient accessibility for wire winding. Each segment can be designed with appropriate slot dimensions that balance these competing requirements.
Solution Approach 2:
The segmentation approach introduces an additional spatial dimension to the winding process, allowing wire access from multiple directions and angles that would not be available in a traditional single-piece stator with reduced slot openings.
3Power
If more wire per slot is used to increase power and reduce circuit resistance, then power density and efficiency improve, but the accessibility and volume for fitting wire around each tooth becomes more difficult
Solution Approach 1:
The segmented stator design provides improved accessibility to each tooth and slot, enabling the fitting of more wire per slot with reduced complexity. Each segment can be independently configured to optimize wire winding access, making it easier to achieve high wire density without proportionally increasing manufacturing complexity.
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 configuration enhances power density, efficiency, and compactness of electrical machines by allowing easier wire access and increased winding volume, reducing weight and volume while maintaining magnetic performance, and enabling different torque outputs for various applications.
Implementation Method 1
Each individual stator has a longitudinal axis, about which a rotor is arranged for rotation. Each individual stator defines an opening which receives the respective rotor.
Data Source
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AI summary
A stator assembly (2) for receiving at least two rotors. The assembly comprises at least two individual stators (4) which are divided into stator segments (14), with at least one segment being a shared segment (14') which forms part of at least two adjacent individual stators. An engine valve actuation assembly includes a stator assembly comprising at least two individual stators. Each individual stator comprises a peripheral portion (10) extending around the longitudinal axis of the stator, with part of the peripheral portion of each stator forming part of the peripheral portion of an adjacent individual stator. Methods for assembling a stator assembly are also described.