Stator Coil End Configuration for Reduced Axial Size
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Solution Overview
Problem
Existing stator designs with concentric winding coils face issues of heavy damage to coil coating due to combined bending of flatwise and edgewise bending, and an enlarged size in the axial direction when bonding positions are set at intermediate positions in the circumferential direction.
Innovation Solution
The design includes radially outer and inner side end portions with oblique portions extending towards each other in the radial and circumferential directions, minimizing the need for combined bending and reducing axial size enlargement by adjusting the bonding position closer to the main body of the coil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bonding position between end portions of two concentric winding coils is set at the intermediate position in the circumferential direction, then the coils can be bonded together, but combined bending (flatwise bending and edgewise bending) is required which causes heavy damage to coil coating
Solution Approach 1:
The patent applies local quality by differentiating the bending requirements at different locations of the coil. The oblique portion is specifically designed to require only edgewise bending while avoiding flatwise bending, creating a localized quality improvement at the bonding end portions compared to the main coil body. This selective bending approach reduces coating damage at the critical bonding locations.
Solution Approach 2:
The patent introduces asymmetry in the coil configuration by creating oblique portions with specific geometries that are asymmetric relative to the main coil body. The radially inner side end portion and radially outer side end portion are designed with asymmetric angles and orientations, allowing them to bond effectively while minimizing the need for combined bending operations that would damage the coating.
2Object-affected harmful factors
If the angle of the oblique portion of the coil that is connected to another conductive wire is made greater than the angle of the oblique portion of the main body of the coil, then combined bending is reduced, but the size of the stator in the axial direction becomes large
Solution Approach 1:
The patent applies parameter changes by optimizing the angles of the oblique portions to achieve a balance between reducing combined bending and controlling axial size. Specifically, the angle of the oblique portion is set within a range of 15° to 45°, which is different from the main body coil angle, creating a parameter change that reduces coating damage while limiting axial dimension increase.
Solution Approach 2:
The patent addresses the axial size issue by utilizing the circumferential direction more effectively. The oblique portions are designed to extend in directions that incorporate circumferential components, allowing the bonding function to be achieved through spatial reconfiguration in multiple dimensions rather than simply increasing the axial dimension.
Data Source
AI summary
A stator that includes an annular stator core having a plurality of slots and a plurality of coils attached to the stator core, the plurality of coils each including a main body that is inserted in the plurality of slots and includes two slot housed portions and coil end portions including oblique portions extending obliquely with respect to the axial direction, a radially first side end portion formed from one of the slot housed portions, and a radially second side end portion formed from the other one of the slot housed portions.