Stator Coil Wiring Layout for Heat and Vibration Resistance
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Solution Overview
Problem
Rotary electric machines face challenges in vibration resistance and heat dissipation due to the arrangement of extension wires and lead wires, leading to increased temperature and reduced performance.
Innovation Solution
The rotary electric machine design incorporates a stator with a disk-shaped base portion and teeth, where coils are divided into systems with specific winding arrangements and phase configurations, and lead wires are managed with clips to reduce wire mass and enhance heat dissipation, while symmetrical fixing holes and clips improve vibration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If extension wires and lead wires are arranged in a conventional manner, then electrical connectivity is achieved, but wire mass increases and vibration resistance deteriorates
Solution Approach 1:
The patent divides the wire arrangement into multiple systems (n systems) where coils are divided by n into n systems. Each system has its own set of extension wires and lead wires that are arranged separately rather than all bundled together. This segmentation reduces the mass concentration and improves vibration resistance by distributing the wire mass more evenly throughout the stator structure.
Solution Approach 2:
The patent arranges extension wires and lead wires in a three-dimensional distribution pattern rather than a simple planar arrangement. Wires are routed through different spatial paths and fixed at multiple points along the stator, transforming the wire arrangement from a two-dimensional bundle to a three-dimensional distributed configuration that reduces mass concentration and improves vibration characteristics.
2Temperature
If extension wires and lead wires are bundled together, then connection is simplified, but heat dissipation deteriorates due to wire congestion
Solution Approach 1:
The patent segments the wire arrangement into n separate systems corresponding to n divisions of the coil set. Each system's extension wires and lead wires are routed independently through different paths in the stator, preventing congestion and improving heat dissipation. The segmentation distributes wire mass and creates channels for heat and air flow.
Solution Approach 2:
The patent utilizes three-dimensional space within the stator to route extension wires and lead wires through multiple dimensions rather than confining them to a single plane. Wires are arranged radially, axially, and circumferentially to distribute them throughout the available volume, reducing local congestion and improving heat dissipation pathways.
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 effectively reduces the temperature rise of coils, enhances vibration resistance, and improves heat dissipation by minimizing wire congestion and optimizing wire arrangement, leading to improved performance and reliability.
Implementation Method 1
A rotor 300 has a plurality of permanent magnets 304 arranged in a circumferential direction
Implementation Method 2
radially outer ends of the teeth face the permanent magnets
Implementation Method 3
The rotary electric machines generate Joule heat
Data Source
AI summary
Coils are divided into “n” systems. Each divided coils are arranged continuously within an angular range obtained by dividing 360 degrees by “n”. A single conductor is wound continuously in a circumferential direction to provide the coils in the same phase. Lead wires and winding start terminals of the coils of the conductors are connected by winding start extension wires. Lead wires and winding end terminals of the coils of the conductors are connected by winding end extension wires. Connection portions to the lead wires are fixed to the stator with clips. The clips are provided with the number “n”, and are located substantially middle to a dividing line that divides into “n”.