Stator Coil-End Layout for Easier Three-Phase Line Routing
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Solution Overview
Problem
Existing rotary electric machines face challenges in arranging three-phase output lines from the connection side coil end, which complicates the assembly process and requires significant structural changes, making it difficult to store them in vehicles with limited space.
Innovation Solution
The solution involves arranging connection-side winding portions with a first and second connection group on one side of the stator core, using segment coils with different slot pitches for the non-connection side coil end, allowing for a twisting process that simplifies the assembly by maintaining the same slot pitch for the connection side coil end.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If three-phase output lines are arranged in the connection side coil end, then the rotary electric machine can be stored within a determined range in vehicles, but the structure needs to be changed considerably and the assembly process becomes complicated
Solution Approach 1:
The coil end is divided into connection-side winding portions and non-connection-side winding portions. The connection-side winding portions are arranged on one side of the stator core and inserted into slots with the same slot pitch, while the non-connection-side winding portions are arranged on the other side and inserted into slots with a plurality of kinds of slot pitches. This segmentation allows the three-phase output lines to be arranged in the connection side coil end without complicating the overall assembly process.
Solution Approach 2:
Different slot pitches are applied to different regions: the connection-side winding portions use slots with the same slot pitch to facilitate uniform twisting and simplify assembly, while the non-connection-side winding portions use slots with a plurality of kinds of slot pitches to achieve the required spatial arrangement for three-phase output lines. This local differentiation resolves the contradiction between compact storage and simple assembly.
2Ease of operation
If coils are arranged with different slot pitches in the connection side coil end, then the three-phase output lines can be arranged, but the twisting process becomes complex and assembly is difficult
Solution Approach 1:
The winding portions are segmented into connection-side and non-connection-side portions with different slot pitch arrangements. The connection-side portions use uniform slot pitches to enable simple twisting processes, while the non-connection-side portions use varied slot pitches to facilitate the arrangement of three-phase output lines without affecting the twisting complexity.
Solution Approach 2:
The patent applies different slot pitch characteristics to different local regions: uniform slot pitches in connection-side slots for easy twisting, and varied slot pitches in non-connection-side slots for easy line arrangement. This local quality differentiation resolves the contradiction between ease of operation and ease of manufacture.
Data Source
AI summary
Provided is a rotary electric machine which is configured to draw three-phase output lines from a connection side coil end by an easy process. A stator for a rotary electric machine according to the present invention includes a plurality of segment coils including connection-side winding portions and non-connection-side winding portions. The connection-side winding portions are arranged on one side of a stator core and connected to slots with the same slot pitch, and the non-connection-side winding portions are arranged on the other side of the stator core and inserted into the slots with a plurality of kinds of slot pitches. The connection-side winding portions include a first connection group and a second connection group. The first connection group is provided with a plurality of terminal portions for connecting the segments, and the second connection group connects layers different from those in the first connection group, and is provided with a plurality of terminal portions.