Segmented Stator Winding Layout for Half-Full-Half Phase Belts
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Solution Overview
Problem
Forming a stator winding arrangement with a half-full-half phase belt is challenging due to complex connections required for high efficiency and low noise in electric machines, particularly with segmented conductors, which are difficult to manufacture without increasing costs.
Innovation Solution
A stator winding arrangement with segmented conductors arranged in layers, featuring alternating pitches in end loops on the stator core, allowing for simple connections and achieving a half-full-half phase belt, which enhances efficiency and reduces noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a half-full-half phase belt winding arrangement is formed to achieve high efficiency and low noise, then the electric machine performance is improved, but the design and manufacturing complexity increases significantly
Solution Approach 1:
The winding arrangement is divided into multiple discrete layers (first through fourth layers) with specific conductor distributions. Each layer is independently configured with particular pitch values, allowing the complex half-full-half phase belt to be constructed from simpler, standardized segment units that can be manufactured and assembled separately.
Solution Approach 2:
Different regions of the winding are assigned different pitch characteristics. Specifically, the first and second layers use pitch P while the third and fourth layers use pitch P-1. This local variation in pitch creates the desired half-full-half phase belt distribution pattern without requiring uniform complexity throughout the entire winding structure.
2Manufacturing precision
If precise connections are made between crowded conductors at the stator core end to achieve the desired winding configuration, then the winding performance is improved, but the manufacturing difficulty and cost increase
Solution Approach 1:
The conductor connections are organized into distinct layers with clear spatial separation. Each layer contains specific conductors that connect to predetermined slots, creating a modular connection structure. This segmentation reduces the crowding problem by distributing connections across multiple layers rather than concentrating them in a single plane.
Solution Approach 2:
The winding arrangement utilizes multiple axial layers to distribute conductors in three-dimensional space rather than confining them to a single plane. By arranging conductors in four distinct layers along the axial direction, the patent creates additional spatial dimensions for connection organization, reducing crowding and improving manufacturability.
Data Source
AI summary
A stator for an electric machine comprises a stator core and a winding positioned on the stator core. The stator core includes a plurality of teeth defining a plurality of slots. The winding is comprised of a plurality of segmented conductors connected together to provide a plurality of parallel paths per phase for the winding, each conductor comprising (i) an end loop provided on a crown end of the stator core, (ii) two legs extending through the slots, and (iii) two leg ends extending out of the slots on a connection end of the stator core, each leg end having a twist portion. The legs of the conductors are arranged in layers in the slots, wherein the layers include a total number of layers (L), L being greater than five and L/2 being an odd whole number. Each leg end extending from each of the layers has a common twist associated with the layer from which said leg extends. The common twist associated with at least half of the layers is a first twist, and the common twist associated with at least one of the layers is a second twist that is different from the first twist.