Stator Coil Conductor Arrangement Reducing Welding Regions
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Solution Overview
Problem
Conventional stators for rotary electric machines have issues with increased component numbers and fabrication costs due to the need for connection rings and protruded conductors, which complicate conductor connections and stator assembly.
Innovation Solution
A stator design with conductors connected in series across multiple slots, using bridge conductors and unit patterns to simplify connections and reduce the number of welding regions, eliminating the need for connection rings and minimizing protrusions, thereby reducing interference and fabrication complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connection rings are used to connect conductors spaced apart by long distances, then electrical conduction between conductors is achieved, but the number of components and fabrication costs increase
Solution Approach 1:
The patent removes the connection ring component entirely by redesigning the conductor layout. Conductors are repositioned within slots so that connection points are adjacent to each other, eliminating the need for separate connection rings and reducing component count while maintaining electrical conduction functionality
Solution Approach 2:
The patent changes the spatial arrangement of conductors from a distributed pattern requiring radial protrusions to a compact pattern within slot layers. By utilizing the layer dimension within slots rather than protruding radially, conductors can be connected directly without connection rings
2Reliability
If conductors are arranged in the middle layer of slots for connection, then connection points are positioned for electrical conduction, but difficulty in connecting conductors with jump lines occurs
Solution Approach 1:
The patent pre-arranges conductors in specific slot positions during the winding process so that connection points are naturally positioned at adjacent locations. This preliminary positioning eliminates the need for complex jump line connections and makes the connection process straightforward
3Reliability
If conductors protrude toward outside of stator in radial direction to avoid interference, then conductor interference is prevented, but case fabrication and installation become difficult
Solution Approach 1:
The patent resolves conductor interference by utilizing the layer dimension within slots rather than protruding in the radial direction. Conductors are arranged in different layers within the same slot, eliminating interference while keeping conductor ends aligned with the stator outer periphery for easy case fabrication
Solution Approach 2:
Instead of protruding conductors outward to avoid interference, the patent inverts the approach by containing conductors within slot layers and using axial positioning to prevent interference, thereby eliminating the need for radial protrusions
4Reliability
If multiple connection rings and protruded conductors are used, then electrical connections are achieved, but fabrication costs and assembly complexity increase
Solution Approach 1:
The patent merges the functions of multiple connection rings into a single integrated conductor arrangement within slot layers. By combining conductor positioning and connection functions into the slot layer structure, the number of separate components is reduced and assembly is simplified
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 design reduces component count and fabrication costs, simplifies conductor connections, and enhances insulation performance by controlling bridge conductor interference and allowing for easier assembly, while also reducing AC resistance and increasing output density.
Implementation Method 1
The rotor is configured to be rotated by an electromagnetic force with the stator
Data Source
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AI summary
A stator for a rotary electric machine includes: a stator core having a plurality of slots; and a stator coil, wherein the stator coil is provided with a plurality of phase windings, wherein each of the plurality of phase windings is provided with 1st to Nth conductors connected to each other in series and spaced apart from each other by 6 slot pitches, wherein each first conductor connected to a power line is arranged in an nth layer, an outermost side in one of the plurality of slots, wherein each of the plurality of phase windings is provided with a plurality of unit patterns connected to each other in series by a bridge conductor, and wherein each conductor connected to the bridge conductor is arranged in a first layer of a corresponding slot. With such a configuration, types of the stator coil may be simplified and the number of welding regions may be reduced.