Stator Connection Bridge Layout for Precise Long-Pitch Windings
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Solution Overview
Problem
Existing methods for forming stator windings in electric rotating machines are limited in accuracy and reliability, particularly in achieving a desired winding arrangement over a large circumferential distance.
Innovation Solution
A stator design that includes a stator core with axial slots arranged circumferentially, where conductors are arranged radially within each slot, and connection bridges with separate base and top elements are used to connect conductors across slots, allowing for precise and reliable formation of windings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If connection bridges are used to connect conductors across slots, then manufacturing precision of winding arrangement is improved, but device complexity increases due to additional components and assembly steps
Solution Approach 1:
The connection bridge integrates multiple functions into a single component: it provides mechanical support for conductors, electrical connection between conductors, and positioning features for accurate winding arrangement. This merging of functions reduces the number of separate components needed while maintaining high manufacturing precision.
Solution Approach 2:
The connection bridge acts as an intermediary element between conductors in different slots, facilitating both mechanical support and electrical connection. This mediator component enables precise winding arrangements by providing a standardized interface for connecting conductors across multiple slots.
2Reliability
If multiple layered insulating supports are used to accommodate connection bridges, then reliability of electrical connection is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The insulating support is divided into functional zones: areas for mechanical locking of connection bridges, areas for electrical insulation, and areas for positioning conductors. This segmentation allows each zone to optimize its specific function while using a single integrated component rather than multiple layered supports.
Solution Approach 2:
The insulating support performs multiple functions simultaneously: providing electrical insulation between conductors and the stator core, mechanically supporting connection bridges, and enabling precise positioning of conductors. This multi-functionality eliminates the need for multiple separate insulating components.
3Ease of manufacture
If connection bridges are designed for limited circumferential distances, then ease of manufacture is improved, but adaptability to different winding arrangements is reduced
Solution Approach 1:
The connection bridge design incorporates adjustable parameters such as the number and position of conductor receiving areas, the length of the bridge, and the configuration of locking features. These parameter variations allow the same basic connection bridge design to accommodate different circumferential distances and winding arrangements while maintaining manufacturing simplicity.
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 approach enables the formation of stator windings with high accuracy and reliability, allowing for complex winding arrangements over large circumferential distances with a simple and efficient manufacturing process.
Implementation Method 1
Respective free end sections of at least some of the conductors are connected to a free end section of another conductor by means of welding to form electrical paths of the stator winding
Data Source
AI summary
The invention relates to a stator which may be used within an electric rotating machine and a method for manufacturing a stator. The stator (200) comprises a stator core (100) having a plurality of slots (101, 101a, 101b) arranged in circumferential direction (C) of the stator core (100), a plurality of conductors (102, 103) forming a stator winding, wherein at least a radially outer conductor (102) and a radially inner conductor (103) are arranged along a radial direction (R) of each slot (101). At least one pair of a radially outer conductor (102) of a first slot (101a) and a radially inner conductor (103) of a second slot (101b) circumferentially spaced from the first slot (101a) is electrically connected by a connection bridge (1). The connection bridge (1) comprises a first base element (2) and a second base element (3) connected to a respective conductor (102, 103) and a top element (4) being connected to the base elements (2, 3) and preferably arranged in a larger distance from the stator core (100) than the first base element (2) and second base element (3).