Segmented Stator Winding Layout for Axial Intermeshing Assembly

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Solution Overview

Problem

The segmentation of stator laminated cores in large rotating electrical machines poses challenges due to the protrusion of rod end faces in two-layer coil windings, making it difficult to assemble heavy stator segments axially and requiring complex connections.

Innovation Solution

A stator design featuring interconnected segments with a two-layer bar winding, where upper and lower bars are connected via a connecting element that allows for axial protrusion, enabling easy assembly and impregnation without the need for additional winding elements, and using a tongue-and-groove connection for mechanical stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a two-layer coil winding is used in segmented stators, then the winding can accommodate segment boundaries, but the rod ends protrude tangentially over long sides of stator segments, preventing axial intermeshing and making assembly difficult

Engineering Contradiction:

Improvewinding adaptability to segmentationVSAvoidassembly ease of stator segments

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The stator is divided into multiple stator segments that can be assembled separately and then connected axially. The winding is also segmented accordingly, with rod ends positioned to enable axial intermeshing between segments rather than protruding tangentially, thus facilitating modular assembly while maintaining electrical continuity across segment boundaries

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of having rod ends protrude tangentially over the long sides of stator segments (conventional approach), the invention inverts the arrangement so that rod ends protrude in a manner that enables axial intermeshing. This inversion of the protrusion direction resolves the assembly difficulty by allowing segments to interlock axially

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If stator segments are assembled with protruding rod ends, then winding continuity can be maintained, but complex connections and additional winding elements are required

Engineering Contradiction:

Improvewinding continuityVSAvoidconnection complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention merges the mechanical connection function with the electrical connection function into a single integrated structure. The rod ends themselves serve as both the mechanical interlocking elements and the electrical conductors, eliminating the need for separate connection elements and reducing overall device complexity while maintaining winding continuity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The rod ends are designed to automatically perform multiple functions: they provide mechanical support, enable axial intermeshing for assembly, and maintain electrical continuity. This self-service approach eliminates the need for additional dedicated connection elements, simplifying the overall structure

Inventive Principle:

Principle #25Self-service

Data Source

PatentEP3959796B1Stator for a rotating electric machine

Publication Date: 2024.05.22 INNOMOTICS GMBH

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AI summary

The invention relates to a stator (2) for a rotating electrical machine (EM), comprising multiple stator segments (2.1, 2.2) and a winding (4) which allows axial telescoping of the stator segments (2.1, 2.2). The invention further relates to a rotating electrical machine (EM) and to a method for assembling a stator (2).