Segmented Stator Winding Layout for Simplified Phase Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing stators for electric machines, particularly in automotive applications, face challenges in achieving efficient and reliable connections between phases due to complex winding configurations and limited manufacturing flexibility.
Innovation Solution
The stator design incorporates a stator core with radially layered slots and shaped conductors that form interconnectable paths in series or parallel, arranged in 2·P winding zones with specific sub-winding zone configurations to simplify phase connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex winding configurations are used to achieve efficient phase connections, then manufacturing reliability improves, but device complexity increases
Solution Approach 1:
The stator winding is divided into multiple independent paths (first path and second path) for each phase, with each path having distinct sections arranged in specific winding zones. This segmentation allows for simplified connection topology while maintaining manufacturing reliability, as each path can be independently manufactured and connected through standardized connectors at the face sides.
Solution Approach 2:
Connectors are introduced as intermediary elements to join shaped conductors at the face sides of the stator core. These connectors simplify the connection process by providing standardized interfaces between winding zones, reducing the complexity of direct conductor-to-conductor connections while ensuring reliable electrical connections.
2Ease of manufacture
If limited manufacturing flexibility is used, then device complexity decreases, but ease of manufacture worsens
Solution Approach 1:
The stator core design with multiple winding zones and sub-winding zones provides a universal platform that can accommodate different winding configurations and connection topologies. The standardized slot structure and face side connectors enable the same physical structure to support various manufacturing approaches, including automated winding processes.
Solution Approach 2:
The winding configuration utilizes the radial dimension by arranging paths and sections in different winding zones and sub-winding zones. This dimensional arrangement allows for simplified two-dimensional connection patterns on the face sides while achieving three-dimensional winding complexity, enabling automated manufacturing with reduced complexity.
3Manufacturing precision
If shaped conductors are arranged in multiple winding zones with alternating connectors, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The stator core is pre-configured with defined winding zones and sub-winding zones before the winding process. This preliminary structuring establishes precise reference positions for connector placement, ensuring that connectors are positioned at correct locations on the face sides. The pre-defined zone structure guides the winding process and maintains manufacturing precision without requiring complex real-time adjustments.
Data Source
AI summary
Stator, which has N≥3 phases, P≥2 pole pairs and a hole count q=2 and also includes a stator core with a plurality of slots and a plurality of shaped conductors. The shaped conductors form for each phase a first and a second path and are arranged in 2·P winding zones which are each subdivided into a first and a second sub-winding zone. The shaped conductors of a respective path are interconnected to form a series connection with a first end-shaped conductor and a second end-shaped conductor by connectors, which connect shaped conductors in adjacent winding zones of the same phase in an alternating manner at two axial face sides. The shaped conductors of a respective path form a first to third section of shaped conductors successively in the series connection. The first and third sections include the first and second end-shaped conductor respectively.