Stator Coil Two-Line Integral Form for Compact Design
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Solution Overview
Problem
The existing stator designs for rotating electric machines require connection rings and jump wires, leading to increased component count, manufacturing costs, and axial and radial size, as well as difficulties in accommodating the stator within a case due to protrusions.
Innovation Solution
A stator design that eliminates connection rings and jump wires by configuring conductors in a two-line integral form, with conductors connected in parallel and welded internally, reducing the number of components and minimizing the stator's size by optimizing conductor placement and connection patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If connection rings and jump wires are used to connect conductors, then the stator coil can be assembled, but the number of components increases and manufacturing cost increases
Solution Approach 1:
The patent merges the functions of connection rings and jump wires into the conductor structure itself by configuring conductors in a two-line integral form with welding portions that directly connect to adjacent conductors. This eliminates separate connection components and reduces the total number of parts while maintaining electrical connectivity.
Solution Approach 2:
The patent extracts and removes the separate connection rings and jump wires from the stator assembly, integrating their connecting function directly into the conductor design through welding portions. This extraction reduces component count and simplifies the overall structure.
2Ease of manufacture
If connection rings are used to connect conductors, then the stator coil can be assembled, but the axial length of the stator increases
Solution Approach 1:
The patent merges the connection function into the conductor body itself through welding portions that extend from conductor ends. This integration eliminates the need for separate connection rings that would increase axial length, thereby compacting the stator structure while maintaining electrical connections.
3Ease of manufacture
If separate connection conductors (jump wires) are used, then conductors can be connected, but the number of welding points increases
Solution Approach 1:
The patent removes separate jump wires from the assembly and integrates their connecting function into the conductor structure. The welding portions are formed as integral parts of the conductors themselves, reducing the number of discrete welding operations required while ensuring reliable electrical connections.
4Ease of manufacture
If conductors are connected in conventional patterns, then the stator coil can be assembled, but connection portions are spaced far apart requiring accommodating portions in the case
Solution Approach 1:
The patent changes the spatial arrangement of connection portions by configuring conductors in a two-line integral form where connection portions are positioned adjacent to each other in the radial direction. This dimensional reorganization eliminates the need for accommodating portions in the case, simplifying the overall structure.
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 AC resistance, decreases the number of components and manufacturing costs, and minimizes the stator's size in both axial and radial directions, enhancing output density and simplifying the manufacturing and installation processes.
Implementation Method 1
Ends of the conductors that are located inside each slot of the plurality of slots are welded together
Data Source
AI summary
A stator of a rotating electric apparatus is disclosed. The stator includes a stator core that defines a plurality of slots that are located a circumference of the stator core. The stator further includes a stator coil that includes a plurality of conductors electrically connected, located in the plurality of slots, and configured to conduct electricity. The stator coil includes a plurality of phase coils that are each connected to a phase of a power source. A first conductor of the stator coil is connected to a power line and is located in an nth layer that is an outermost layer of one of the plurality of slots. An Nth conductor of the stator coil is connected to a neutral line and is located in an n−1th layer that is located nearer to a center of the stator than the nth layer.