Stator Coil Layout That Avoids Phase-to-Phase Insulation
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Solution Overview
Problem
The need for phase-to-phase insulation increases due to double-wound coils of different phases being close to each other in the radial direction, leading to higher potential differences and increased costs in stators for rotating electrical machines.
Innovation Solution
A stator design with double-wound coils that are arranged such that only specific phases overlap in a circumferential section, with slot insertion portions of different phases inserted into different slots, reducing the need for phase-to-phase insulation by ensuring adequate electrical insulation distances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If double-wound coils of different phases are arranged close to each other in the radial direction, then the stator can achieve compact design and reduced size, but phase-to-phase insulation measures become necessary increasing cost and complexity
Solution Approach 1:
The patent transitions from radial arrangement to circumferential arrangement of double-wound coils. By positioning coils of different phases at different circumferential positions rather than radially adjacent, the design achieves compactness without requiring phase-to-phase insulation measures, thus resolving the contradiction between size reduction and insulation complexity
Solution Approach 2:
The patent applies different arrangement strategies to different phases: double-wound coils of the same phase are arranged radially adjacent to each other, while coils of different phases are positioned at different circumferential positions. This localized differentiation allows compact design while eliminating the need for phase-to-phase insulation
2Ease of manufacture
If one type of double-wound coil is used for all phases, then the number of coil types is reduced simplifying manufacturing, but phase-to-phase insulation becomes necessary due to potential difference
Solution Approach 1:
The patent uses the circumferential dimension to separate coils of different phases, allowing the use of identical double-wound coil types across all phases without requiring phase-to-phase insulation. This spatial separation in the circumferential direction resolves the contradiction between manufacturing simplicity and insulation complexity
3Power
If double-wound coils of different phases are positioned far from the neutral point, then higher potential difference is achieved improving performance, but the need for phase-to-phase insulation increases
Solution Approach 1:
The patent positions high-potential double-wound coils at different circumferential positions rather than radially adjacent positions. This circumferential separation maintains the high potential difference needed for performance while eliminating the need for phase-to-phase insulation, resolving the contradiction between power output and insulation complexity
Data Source
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AI summary
A stator for a rotating electrical machine is disclosed that includes a stator core and a stator coil of a plurality of phases. The stator coil of the plurality of phases is formed by winding a plurality of double-wound coils of each phase around the stator core along an entire circumference of the stator core. Each of the plurality of double-wound coils concentrically include a coil portion with a larger circumference length and a coil portion with a shorter circumference length. The double-wound coil of each phase includes a first double-wound coil farthest from a neutral point and a second double-wound coil other than the first double-wound coil. Of the first double-wound coils of first to third phases, only the combination of the first double-wound coils of the first and second phase overlaps in a specific circumferential section corresponding to at least one slot, and the first double-wound coils of different phases are inserted in different slots.