Serial Stator Coil Winding Chains for Simpler Assembly
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Solution Overview
Problem
The construction and production of stator windings in electric machines are complex and time-consuming, especially for high-pole pair machines, due to the need for extensive electrical connections between individual windings, which also results in a heavy and complex apparatus.
Innovation Solution
A stator winding system where windings are formed from a continuous electric conductor, eliminating the need for separate intermediate connections, and utilizing an interconnection unit with paired contact points to simplify the assembly of sub-winding systems by connecting winding chains in series, allowing for direct winding onto stator teeth or formation as air coils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individual windings are electrically connected using separate intermediate pieces, then the stator winding system can be assembled, but the apparatus becomes complex and heavy with high production time expenditure
Solution Approach 1:
Multiple individual windings are merged into a single continuous winding chain formed from one piece of electric conductor. This combining eliminates the need for separate intermediate connection pieces between windings, directly reducing apparatus complexity and production time while maintaining electrical connectivity.
Solution Approach 2:
The stator winding system is segmented into multiple winding chains, where each winding chain consists of windings connected in series from a continuous conductor. This segmentation allows independent production and assembly of winding chains, simplifying the overall manufacturing process and reducing the complexity of assembling numerous individual windings.
2Reliability
If multiple separate connection pieces are used to connect windings, then electrical connectivity is achieved, but the apparatus weight increases
Solution Approach 1:
The elimination of separate intermediate connection pieces by merging windings into continuous winding chains directly reduces the total weight of the stator winding system while maintaining reliable electrical connectivity through the continuous conductor structure.
3Ease of manufacture
If windings are connected through multiple intermediate pieces, then the winding system can be constructed, but the risk of insulation damage increases
Solution Approach 1:
By combining multiple windings into a single continuous winding chain from one piece of conductor, the number of connection points and intermediate pieces is eliminated, thereby removing the sources of potential insulation damage while maintaining construction feasibility.
4Adaptability or versatility
If numerous individual windings are electrically connected, then the machine achieves high pole pairs configuration, but the production time and apparatus complexity increase significantly
Solution Approach 1:
The high pole pairs configuration is achieved by creating multiple winding chains that can be independently produced and then assembled. This segmentation approach allows parallel production of winding chains, significantly reducing overall production time compared to assembling numerous individual windings sequentially.
Solution Approach 2:
Multiple windings are merged into continuous winding chains, reducing the number of assembly operations required. This merging enables faster construction of the stator winding system while maintaining the high pole pairs configuration through the series-connected winding chains.
Data Source
AI summary
A stator winding system for a stator of an electric machine is provided. The stator has a number of windings to be positioned on stator teeth of the stator. At least two windings that follow one another in a current flow direction of an electric current and are thus arranged in series are formed from an electric conductor that is continuous in the current flow direction, forming a winding chain.