Segmented Stator Winding for Complete Two-Layer Installation
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Solution Overview
Problem
Electrical machines with stators divided into segments face challenges in implementing a high-quality two-layer winding, leading to incomplete windings and electromagnetic disadvantages, which complicates manufacturing and reduces operational safety.
Innovation Solution
The stator segments are designed such that the first transition webs end below the middle groove webs, with overlapping transition areas, allowing for complete two-layer winding installation before assembly, eliminating the need for subsequent winding introduction and ensuring consistent winding design across segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the stator is divided into multiple segments for easier manufacturing, transport and storage, then manufacturing and transport efficiency are improved, but implementing a complete two-layer winding becomes difficult and the electromagnetic performance deteriorates
Solution Approach 1:
The stator is divided into multiple stator segments that can be manufactured, transported and assembled separately. Each segment contains portions of the two-layer winding, and the segments are designed to connect magnetically to form a complete two-layer winding structure when assembled together, thereby maintaining electromagnetic performance while improving manufacturing efficiency.
Solution Approach 2:
The two-layer winding is pre-installed on each stator segment during segment manufacturing, before the segments are assembled into the complete stator. This preliminary winding installation ensures that each segment has the correct electromagnetic structure, and when segments are assembled, the windings connect to form a complete two-layer winding system.
2Ease of manufacture
If a single-layer winding is used in segmented stators to simplify manufacturing, then ease of manufacture is improved, but electromagnetic disadvantages occur
Solution Approach 1:
The two-layer winding is segmented across multiple stator segments. Each segment contains a portion of the winding layers, and when segments are assembled, the windings connect to form the complete two-layer structure, achieving both manufacturing simplicity and electromagnetic performance.
Solution Approach 2:
Each stator segment is designed with specific local features including transition regions with varying web heights. The transition webs connect segments and maintain the two-layer winding structure at segment boundaries, ensuring consistent electromagnetic performance across all segments while allowing simplified manufacturing of individual segments.
3Reliability
If transition areas of adjacent stator segments overlap, then complete two-layer winding installation is enabled, but structural complexity increases
Solution Approach 1:
The stator is segmented with overlapping transition regions that contain the winding connections. This segmentation allows each segment to be manufactured independently with partial windings, which connect to form the complete two-layer winding when segments are assembled together.
Solution Approach 2:
The windings are preliminarily installed on each stator segment before assembly, including the transition webs that will connect to adjacent segments. This preliminary winding installation ensures that when segments are assembled with overlapping transition areas, the complete two-layer winding structure is automatically formed without requiring additional winding operations.
Data Source
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AI summary
The invention relates to a rotor (2) of an electric machine which is movable relative to a stator (1) of the electric machine in a direction of movement (x). Viewed in the direction of movement (x) the stator (1) is divided into stator segments (10) which each have a central region (11) and two transition regions (12, 13). Viewed in the direction of movement (x) of the rotor (2) the central regions (11) are disposed between the transition regions (12, 13). On the side facing away from the rotor (2) stator yokes (14) of the stator segments (10) extend in each case over the central region (11) and the first transition region (12). Starting from the stator yokes (14), central groove webs (16) in the central regions (11) and first transition webs (17) in the first transition regions (12) extend towards the rotor (2). The first transition webs (17) end below the central groove webs (16). On the side of the stator segments facing away from the rotor (2) the stator segments (10) each have in the second transition regions (13) a transverse web (18) from which second transition webs (19) extend towards the rotor (2). The second transition webs (19) end at the same height as the central groove webs (16). Viewed in the direction towards the rotor (2), lower edges (15) of the stator yokes (14) have a yoke spacing (a1) from the rotor (2). Viewed in the direction towards the rotor (2), a spacing (a3) of the first transition webs (17) from the rotor (2) is at least as big as the spacing (a5) of a lower edge (20) of the transverse webs (18). Viewed in the direction of movement (x) of the rotor (2), the transition regions (12, 13) of stator segments (10) which adjoin one another overlap one another and are disposed one above the other when viewed from the stator (1) towards the rotor (2).