Stator Tooth Coil Contours for Higher Slot Space Factor
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Solution Overview
Problem
Current motor manufacturing techniques for splicing single teeth into a circle to form an annular stator core limit the slot space factor, restricting the number of turns that can be wound and thus the motor's efficiency and power density.
Innovation Solution
A stator core structure comprising I-shaped single teeth with different winding modes for each tooth, allowing a staggered arrangement and varying coil contours, which increases the slot space factor by optimizing coil placement and utilizing insulating spacers for better insulation and space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If single teeth are spliced into a circle with consistent winding modes, then the manufacturing process is simple and convenient, but the slot space factor is limited
Solution Approach 1:
The patent applies asymmetry by introducing different winding modes (first winding mode and second winding mode) for alternating single teeth in the stator core. Specifically, teeth with odd numbers use the first winding mode while teeth with even numbers use the second winding mode, creating asymmetric coil arrangements that optimize space utilization and increase the slot space factor beyond conventional symmetric designs.
Solution Approach 2:
The patent implements local quality by allowing different winding characteristics in different regions of the stator core. Each single tooth can have customized winding parameters (such as winding direction, coil layout, or turn density) according to its position and function, enabling optimal local space utilization while maintaining overall manufacturing feasibility.
2Quantity of substance
If the slot space factor is increased by optimizing coil arrangement, then more turns can be wound, but the coil arrangement complexity increases
Solution Approach 1:
The patent divides the stator core into multiple independent single teeth, each capable of being wound separately with different winding modes. This segmentation allows complex overall arrangements to be achieved through simple, repetitive local operations on each tooth, reducing the actual manufacturing complexity despite the sophisticated final configuration.
Solution Approach 2:
Instead of attempting to wind complex multi-turn coils in a single continuous operation, the patent inverts the approach by using multiple simpler winding modes on alternating teeth. This inversion transforms a potentially complex single-operation problem into multiple simpler operations that are easier to execute and control.
Data Source
AI summary
An embodiment provides a stator core including a plurality of first single teeth, a plurality of second single teeth and coils. The teeth are I-shaped and each have a long side, a short side, a connection portion and a wire-accommodating slot located on the sides of the connection portion. The coils are wound around the connection portions and accommodated in the wire-accommodating slots. The stator core is an annular element formed by splicing first single teeth and second single teeth in sequence in a staggered manner into a circle, and winding modes of the coils on the first single teeth and the second single teeth are different, so that the contour of the coils located on the outer side of the wire-accommodating slots of the first single teeth is different from the contour of the coils located on the outer side of the wire-accommodating slots of the second single teeth.