Staggered Flat-Wire Wave Winding for Single Three-Phase Control
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Solution Overview
Problem
Existing motor stator windings with wave-wound coil configurations require multiple controllers due to uneven slot distribution per pole per phase, leading to complex motor circuits and high manufacturing costs.
Innovation Solution
A flat-wire continuous wave-wound staggered winding design that adjusts the pitch of S-shaped wave wires in each phase to synchronize current flow across different slots, allowing for single three-phase control by staggering the winding portions according to the number of slots per pole per phase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wave-wound coil configuration is used with equal pitch for all wires in each phase, then the winding structure is simple and easy to manufacture, but multiple controllers are required leading to complex motor circuits and high manufacturing costs
Solution Approach 1:
The patent applies asymmetry by setting different pitches for different wires within the same phase. Specifically, the first wire has pitch y1 and the second wire has pitch y2 where y1 ≠ y2. This asymmetric pitch configuration allows currents from different slots to be synchronized, enabling single three-phase control and simplifying the motor circuit while maintaining manufacturing simplicity.
2Adaptability or versatility
If multiple controllers are used to control motors with different slot distributions, then the motor can operate with various configurations, but the manufacturing cost increases and the circuit design becomes complicated
Solution Approach 1:
The patent achieves universality by creating a winding configuration that works for motors with different slot distributions per pole per phase. The asymmetric pitch design (y1=q×m+(q−1) and y2=q×m−1) allows the same winding structure to synchronize currents regardless of the specific q value, enabling single three-phase control for motors with 2, 3, 4, or more slots per pole per phase without requiring additional controllers.
3Productivity
If equal pitch is used for all wave wires in each phase, then the winding process is simplified, but current flow cannot be synchronized across different slots requiring multiple controllers
Solution Approach 1:
The patent applies local quality by giving different pitch values to different wires within the same phase based on their specific positions and functions. The first wire uses pitch y1=q×m+(q−1) while the second wire uses pitch y2=q×m−1. This localized differentiation in pitch values ensures that currents from different slots are synchronized when they reach the common busbar, achieving reliable current synchronization while maintaining an efficient winding process.
Data Source
AI summary
The present invention discloses a flat-wire continuous wave-wound staggered winding and a stator including same, relating to the technical field of motor manufacturing. The flat-wire continuous wave-wound staggered winding consists of an incoming line end wire portion, an outgoing line end wire portion, and S-shaped wave wires. The S-shaped wave wires include an effective side portion, a straight wire portion, and an end portion, wherein a staggered winding portion is provided in the S-shaped wave wires. The staggered winding portion is arranged in a staggered manner between the wires in each phase of the wires. The present invention achieves single three-phase control for motors or generators with different numbers of slots distributed per pole per phase, thereby simplifying motor circuits and reducing manufacturing costs. The second harmonic of the motor can be reduced, and the noise of the motor can be lowered, thereby improving the product quality.


