Stator Coil Segmentation for Electric Rotating Machine Manufacturing
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Solution Overview
Problem
Conventional stator manufacturing for electric rotating machines requires long electric wires, leading to high costs and low productivity due to handling difficulties and potential interference with the rotor, which reduces stator reliability.
Innovation Solution
A stator coil configuration using multiple electric wires with in-slot and turn portions, where each phase winding is formed from at least two wires, allowing for shorter wire lengths and improved handling, and the first and second end portions are positioned to facilitate easy connection and reduce interference with the rotor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If each phase winding is formed using a single long electric wire, then the wire can be continuously wound into a spiral shape, but the wire length becomes excessively long requiring large-scale shaping machines and difficult handling
Solution Approach 1:
The patent divides each phase winding into multiple separate electric wires (first electric wire, second electric wire, third electric wire, etc.) instead of using a single continuous long wire. Each wire has a manageable length that can be easily handled and shaped using small-scale shaping machines, thereby resolving the contradiction between ease of manufacture and wire length.
2Shape
If electric wires are wound into spiral shape and received in slots, then the stator coil achieves compact cylindrical form, but interference occurs due to springback between stator coil and rotor
Solution Approach 1:
By segmenting the phase windings into multiple separate wires, the patent reduces the springback effect that occurs when wires are wound into spiral shapes. The shorter, segmented wires can be more precisely positioned and secured in the slots, preventing interference with the rotor while maintaining the compact cylindrical form of the stator coil, thus resolving the contradiction between shape and reliability.
3Productivity
If long electric wires are used to form phase windings, then continuous winding is possible, but productivity decreases due to handling difficulties and manufacturing complexity
Solution Approach 1:
The patent segments each phase winding into multiple shorter electric wires, which can be manufactured using simple small-scale shaping machines rather than complex large-scale equipment. This segmentation enables easier handling, simpler manufacturing processes, and higher productivity, effectively resolving the contradiction between productivity and device complexity.
Data Source
AI summary
A stator includes a stator core and a multi-phase stator coil comprised of a plurality of electric wires. Each of the electric wires has first, second, . . . , nth in-slot portions and first, second, . . . , (n−1)th turn portions, where n is an integer not less than 4. The first in-slot portions of the electric wires are located most radially outward and the nth in-slot portions are located most radially inward in the slots of the stator core. Each of the electric wires also has a first end portion positioned on the first in-slot portion side and a second end portion positioned on the nth in-slot portion side. Each of phase windings of the stator coil is formed of at least two of the electric wires. The first end portion of one of the two electric wires is connected to the second end portion of the other electric wire.