Segmented Stator End Turn Volume Reduction
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Solution Overview
Problem
The structural volume required for end windings of preformed coils in electrical machines is not optimized, leading to challenges in assembly and transportation of large machines, as conventional designs prevent the use of inwardly directed end windings due to space constraints.
Innovation Solution
A segmented stator design with preformed coils having inwardly directed end windings allows for assembly around a rotor, enabling easier disassembly and transportation, achieved by bending end windings inwardly and using two identical coil types with different orientations, and incorporating a third uncranked coil for denser packing and reduced overhang.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If preformed coils with outwardly directed end windings are used in a conventional complete hollow cylinder stator, then the rotor can be pushed into the stator, but the structural volume required by the end windings is large and assembly/disassembly is difficult
Solution Approach 1:
The stator is divided into multiple arc-shaped segments that can be assembled together to form a complete hollow cylinder. This segmentation allows the stator to be disassembled for easy transportation and enables the use of inwardly directed end windings that would otherwise prevent rotor insertion. The segments are connected through connection elements to maintain structural integrity while allowing disassembly.
2Volume of moving object
If preformed coils with inwardly directed end windings are used, then the structural volume of end windings is reduced, but the rotor cannot be pushed into the stator in a conventional complete hollow cylinder design
Solution Approach 1:
The stator is segmented into arc-shaped elements that can be assembled around the rotor in a step-by-step process. This allows the preformed coils with inwardly directed end windings to be installed on the segments before final assembly, enabling the rotor to be pushed into the incomplete stator structure and then have the remaining segments closed around it.
Solution Approach 2:
The preformed coils are prepared in advance with their end windings directed inwardly, and the stator segments are pre-assembled with these coils installed before the final assembly with the rotor. This preliminary preparation enables the unique assembly sequence where the rotor is inserted first, followed by closing the stator segments around it.
3Adaptability or versatility
If multiple coil variants with different cranking orientations are used, then overlapping of preformed coils is enabled, but the number of coil variants increases manufacturing complexity
Solution Approach 1:
A single type of preformed coil with inwardly directed end windings serves multiple functions: it can be installed on different stator segments, and the inwardly directed configuration enables both compact packing and compatibility with the segmented stator-rotor assembly approach. This universal coil design eliminates the need for multiple coil variants with different cranking orientations.
Data Source
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AI summary
The invention relates to an end turn arrangement in a stator of a dynamoelectric machine. In order to reduce, in a simple fashion, the volume required for the end turns of the form-wound coils, the stator is formed of segments (1) that have a substantially circular arc-shaped cross-section and can be combined into a stator by adding one or more other segments (1) having the same design. Each segment (1) has recesses (6, 7), within which at least one first form-wound coil (3), which is bent outward in the radial direction of the stator in the region of the end turns, and at least one second form-wound coil (4), which is bent inward in the radial direction of the stator in the region of the end turns, are arranged in the form of a tiered winding.