Stator Coil Terminal Layout for Easier Braiding and Rotor Rotation
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Solution Overview
Problem
Conventional stator coils face challenges in arranging input and midpoint terminals in a continuous manner, leading to complex coil formation and difficulty in braiding strip-shaped coils, which results in poor formability and hindered rotor rotation.
Innovation Solution
The stator coil design alternately arranges input terminals and midpoint terminals along the length direction, allowing for optimal phase coil arrangement within the stator core slots and enabling simultaneous braiding of coils, thus improving formability into a sheet shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If input terminals and midpoint terminals are arranged in conventional order (U, V, W, Nu, Nv, Nw), then electrical connection is achieved, but coil formation becomes complicated and braiding becomes difficult
Solution Approach 1:
The patent inverts the conventional terminal arrangement by placing midpoint terminals and input terminals in an alternating sequence (Nu, U, Nv, V, Nw, W) rather than grouping all input terminals together followed by all midpoint terminals. This inversion simplifies the coil formation process and enables easier braiding of strip-shaped coils while maintaining proper electrical connections.
2Ease of manufacture
If input terminals and midpoint terminals are closely arranged in alternating order, then formability improves, but current orientation in adjacent slots becomes problematic
Solution Approach 1:
The patent applies local quality by differentiating the arrangement of straight portions for different phases. Specifically, straight portions of the U-phase and W-phase are arranged to extend in one direction, while straight portions of the V-phase are arranged to extend in the opposite direction. This local differentiation ensures proper current orientation in adjacent slots while maintaining the simplified alternating terminal arrangement that improves formability.
3Device complexity
If straight portions are arranged with same orientation in adjacent slots, then coil structure is simplified, but rotor rotation becomes hindered
Solution Approach 1:
The patent implements local quality by assigning different orientations to straight portions based on their phase and position. Straight portions in the U-phase and W-phase extend in one direction, while straight portions in the V-phase extend in the opposite direction. This localized variation in orientation ensures that current flows in the correct direction through adjacent slots, enabling smooth rotor rotation while maintaining a relatively simple overall coil structure.
Data Source
AI summary
A stator coil includes a coil group of coils of three phases of a U-phase, a V-phase and a W-phase, each including a plurality of straight portions inserted into slots of a stator core, the coil group being folded back in a state where input terminals and midpoint terminals are closely arranged, so that forward portions and backward portions of the plurality of straight portions are laminated, and the input terminals and the midpoint terminals of the respective three-phase coils are alternately arranged in a length direction of the stator coil.