Stator Coil Radial Stacking for Axial Length Reduction
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Solution Overview
Problem
The existing stator designs with coaxially wound coils experience an increase in axial length due to bent coil end portions, which can lead to an overall longer stator length, compromising efficiency and space utilization.
Innovation Solution
The method involves manufacturing stators with coaxially wound and wave wound coils, where the coils are inserted into slots with a larger circumferential clearance, allowing the coil end portions to be stacked radially without bending, thereby preventing axial length increase. This is achieved by adjusting the clearance between slot housed and slot housed portions, ensuring the coils are inserted with their conductor wires stacked radially, and using offset portions with specific width and angle configurations to prevent interference and deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If coil end portions are bent radially inward to be stacked on each other in the axial direction, then coils can be housed in slots, but the axial length of the stator increases
Solution Approach 1:
The patent changes the stacking direction of conductor wires from the axial direction to the radial direction. By having conductor wires stacked on each other in the radial direction rather than the axial direction, the coil end portions can be housed in slots without increasing the axial length of the stator, thus resolving the technical contradiction between ease of manufacture and axial length.
2Length of moving object
If conductor wires are stacked radially without bending coil end portions, then axial length is reduced, but clearance control between adjacent coils becomes critical
Solution Approach 1:
The patent specifies precise parameter ranges for the clearance between slot housed portions of adjacent continuous coils. By controlling the clearance to be within a specific range (0.5 mm to 2.0 mm), the patent enables radial stacking of conductor wires without increasing axial length while maintaining manufacturability and preventing interference during assembly.
3Reliability
If offset portions are added to coil end portions, then interference between adjacent coils is prevented, but device complexity increases
Solution Approach 1:
The patent introduces offset portions only at specific locations (coil end portions) rather than modifying the entire coil structure. This localized modification prevents interference between adjacent continuous coils while maintaining the simplicity of the overall coil structure, thus resolving the contradiction between reliability and device complexity.
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5B
AI summary
A stator is configured such that the clearance in the circumferential direction between a slot housed portion of a first continuous coil and a slot housed portion of a second continuous coil after the first continuous coil and the second continuous coil are housed in slots is larger than the clearance before the first continuous coil and the second continuous coil are housed in the slots.