Segmented Stator Winding Layout for Compact High-Torque Motors
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Solution Overview
Problem
Conventional electric machines have inefficiencies due to winding ends projecting beyond the stator's active length, causing ohmic losses and limited torque generation, especially in applications with limited axial space.
Innovation Solution
A stator design with multiple plates and teeth arranged to enclose electrical conductors within the stator, eliminating protruding winding ends and allowing for radial flux, enabling efficient torque generation across the entire stator length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional windings are used with ends projecting beyond the stator, then the winding structure is simple to manufacture, but ohmic losses increase and torque generation is limited
Solution Approach 1:
The stator is segmented into multiple discrete plates (first plates, second plates) arranged axially, with windings confined between them. This segmentation allows the winding ends to be contained within the stator structure rather than projecting outward, reducing ohmic losses while maintaining manufacturing feasibility through modular plate assembly
Solution Approach 2:
The winding arrangement transitions from a conventional two-dimensional planar layout to a three-dimensional configuration confined between stator plates. The windings are arranged radially and axially within the stator body, utilizing the third dimension (axial direction) to contain the entire winding length within the active stator length, eliminating protruding ends
2Power
If the stator active length is increased to improve torque generation, then more torque can be generated, but the axial space requirement increases
Solution Approach 1:
Different regions of the stator are assigned different functions: first plates and associated windings generate torque in one axial region, while second plates extend the magnetic circuit and provide flux return paths in another axial region. This local differentiation allows efficient use of axial space, maximizing torque generation within a compact overall length by optimizing each axial segment's contribution
Solution Approach 2:
The stator plates serve multiple functions simultaneously: they provide structural support, establish magnetic flux paths, contain the windings within the active length, and enable torque generation. The first plates act as both winding supports and torque-generating elements, while second plates provide both structural closure and flux return paths, reducing the need for additional dedicated components that would increase axial length
3Ease of manufacture
If winding ends are allowed to project beyond the stator, then the windings can be easily assembled, but the overall machine length increases and space efficiency decreases
Solution Approach 1:
The windings are nested within the stator structure by confining them between the first and second plates. The entire winding length is contained within the axial boundaries of the stator, with no protruding ends. This nesting arrangement maintains assembly simplicity through the modular plate structure while achieving compact overall dimensions
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 design enhances torque generation efficiency, reduces losses, and allows for a compact, flat electric machine suitable for applications with limited space, such as robotics, while utilizing space effectively and reducing costs.
Implementation Method 1
The currents flowing through the windings generate unnecessary ohmic losses in the end region
Implementation Method 2
In operation, a magnetic field of the rotor interacts with a magnetic field of the stator
Implementation Method 3
The first plates may each comprise steel or magnetic steel. Further, it is possible that the first plates each comprise soft magnetic powder composites
Data Source
AI summary
A stator for an electric machine is provided, the stator comprising at least three first plates at a first side of the stator, at least three teeth, each tooth being mechanically connected to a respective one of the first plates, and at least one second plate at a second side of the stator facing away from the first side, wherein the stator has, at least in some places, the shape of a ring having an outer side and an inner side, an electrical conductor is assigned to each tooth, and for each tooth, the respective electrical conductor is arranged at least at one side of the tooth which points towards the outer side of the stator and at one side of the tooth which points towards the inner side of the stator. Further, a rotor for an electric machine and an electric machine are provided.