Segmented Winding Head Structure for Higher Stator Fill Factor
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Solution Overview
Problem
Prior art stators for permanent magnet synchronous machines have limited fill factors and poor heat transfer, leading to suboptimal mechanical and electrical performance, especially at high operating frequencies, and are heavy for aerospace applications.
Innovation Solution
A winding head for a stator tooth with an I-shaped cross section and flanges joined by a joint part, featuring a winding hole, groove, and support structure to enhance mechanical characteristics and improve fill factor, allowing a robust stator design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If stator coils are machined directly around single-part stator teeth, then the design of coils is flexible and simple, but the fill factor is limited and heat transfer is poor
Solution Approach 1:
The stator tooth is divided into multiple parts: a stator core with I-shaped cross section and two separate winding heads that are joined together. This segmentation allows the winding heads to be positioned optimally around the stator core, improving the fill factor of the stator coils while maintaining manufacturing simplicity through modular assembly
2Ease of manufacture
If stator coils are machined directly around single-part stator teeth, then the coil design is flexible and simple, but heat transfer between turns and to the stator coil is low
Solution Approach 1:
By segmenting the stator tooth into stator core and separate winding heads, the winding heads can be positioned to optimize thermal contact between coil turns and the stator core, improving heat transfer while keeping the manufacturing process simple and modular
Solution Approach 2:
The winding heads are designed with specific local features including a groove in the joint part and support structures that create optimal contact surfaces. These local quality improvements enhance heat transfer pathways from the coil turns to the stator core without complicating the overall manufacturing approach
3Ease of manufacture
If prior art stator design is used, then manufacturing is simple, but mechanical and electrical performance is limited at high operating frequencies
Solution Approach 1:
The segmented design with separate winding heads joined to the stator core allows for optimized electrical characteristics at high frequencies while maintaining manufacturing simplicity through modular assembly. The groove and support structures in the joint part ensure reliable electrical performance
Data Source
AI summary
A winding head for a stator tooth of an electric motor is provided. A stator core has a first stator flange and a second stator flange that are joined by a stator joint part. The stator core has an I-shaped cross section perpendicular to a longitudinal elongation with a first end and a second end. The winding head is configured to extend the longitudinal elongation at the first end. The winding head has a first winding head flange and a second winding head flange that are joined by a winding head joint part, and the winding head extends at least partially an elongation of a shape of the stator core. The winding head also has a winding hole at the first winding head flange and a winding opening at the winding head joint part. The winding hole and opening are connected by a groove in the winding head joint part.