Stator Coil Curved Corner Segments for Compact Winding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Concentrated winding stator coils with straight-line lane change segments face challenges in downsizing electromagnetic devices due to increased winding size, limiting their application in space-constrained vehicles where high output power is required.
Innovation Solution
The stator coil design incorporates unit winding subparts with a combination of straight-line and curved segments, where incline segments are formed by bending conductors to shift pitch-wise, allowing for efficient layer transitions and reduced dimensions, and a manufacturing method that presses and bends conductors to create curved corner segments for layer transition segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If straight-line lane change segments are formed in concentrated winding stator coils, then layer transition is achieved, but the winding size increases making downsizing difficult
Solution Approach 1:
The patent applies curvature by forming curved corner segments instead of straight-line segments for lane changes. The conductor is bent at corners to create curved paths that naturally incorporate the pitch shift, eliminating the need for additional straight-line incline segments and reducing overall winding dimensions.
Solution Approach 2:
The patent merges the corner rounding function with the lane change function by designing curved corner segments that simultaneously serve as both the corner transition and the pitch-shifting incline segment. This integration eliminates separate components and reduces winding size.
2Ease of manufacture
If the conductor is bent to form incline segments for pitch shifting, then layer transition is enabled, but manufacturing complexity increases
Solution Approach 1:
The patent simplifies manufacturing by using curved corner segments that naturally provide the pitch shift through their geometry. The curved shape is easier to form using standard bending processes compared to creating precise straight-line incline segments with specific angles and lengths.
Solution Approach 2:
The patent changes the geometric parameters of the corner segments from straight lines to curved paths, which alters the manufacturing approach from precision angular bending to more forgiving radial bending processes, reducing manufacturing complexity.
Data Source
AI summary
A stator coil that is wound by concentrated winding and installed in a slot of a stator includes a winding part in which a conductor is wound pitch by pitch around a tooth of the stator and connection terminals which extend from both ends of the winding part. The winding part includes a plurality of unit winding subparts of a rectangular annular shape, a unit winding subpart including a pair of first straight-line segments, a pair of second straight-line segments, and curved corner segments which join the first straight-line segments and the second straight-line segments. In one of the pair of first straight-line segments, incline segments where the conductor is shifted by one pitch toward a winding axis direction are formed. In at least one of the unit winding subparts, a part of an incline segment is made by a part of each of the curved corner segments.