Stator Coil Wiring Simplification for Rotary Electric Machines
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Solution Overview
Problem
There is a need for a simplified wiring configuration for the three-phase windings of rotary electric machines, particularly in vehicles, as existing configurations are complex and not explicitly provided, leading to increased manufacturing difficulties and potential interference issues.
Innovation Solution
The rotary electric machine incorporates a stator core with circumferentially spaced slots and a stator coil comprising first and second sets of three-phase windings, where the output ends of each set are connected in delta configuration, with the second set's input ends connected to the first set's junctions, and the windings are arranged to minimize overlap and simplify connections, allowing for easier manufacturing and reduced magnetic noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the three-phase windings are connected in delta configuration with multiple sets and groups, then the number of turns can be freely set and magnetic noise decreases, but the wiring configuration becomes complex and manufacturing becomes difficult
Solution Approach 1:
The patent combines multiple sets and groups of three-phase windings into a unified stator coil structure where the first and second sets are integrated within the same stator coil. The delta configuration merges the windings such that junctions of the first set connect to input ends of the second set, creating a consolidated wiring arrangement that reduces complexity while maintaining the noise-reduction benefits of multiple windings.
Solution Approach 2:
The patent employs asymmetric winding arrangements where the first and second sets of three-phase windings have different numbers of turns and are positioned at different locations within the stator coil. This asymmetric configuration allows flexible turn count optimization for each set while the asymmetric connection pattern (delta configuration) simplifies the overall wiring structure compared to symmetric multi-set arrangements.
2Adaptability or versatility
If multiple sets and groups of three-phase windings are used, then design flexibility increases, but the wiring configuration is not explicitly provided and manufacturing becomes more difficult
Solution Approach 1:
The patent segments the stator coil into distinct first and second sets of three-phase windings, each with independent turn counts and positions. This segmentation provides design flexibility for optimizing performance parameters while the segmented structure with clear delta configuration connections simplifies manufacturing by allowing each set to be wound and connected independently according to the specified pattern.
Solution Approach 2:
The patent enables independent parameter optimization for each set of windings, specifically the number of turns, which can be freely adjusted for the first and second sets. This parameter flexibility maintains design adaptability while the standardized delta connection method provides a consistent manufacturing approach that simplifies production despite the variable parameters.
3Ease of manufacture
If the windings are arranged to minimize overlap, then manufacturing becomes easier and connections are simplified, but the space utilization in slots may be reduced
Solution Approach 1:
The patent arranges the first and second sets of three-phase windings in different spatial dimensions within the stator coil structure. The windings are disposed at different locations and orientations, utilizing three-dimensional space within the slots rather than overlapping in the same plane. This dimensional arrangement simplifies connections by reducing overlap while maintaining efficient slot space utilization through vertical and radial positioning variations.
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 configuration simplifies the wiring connections, reduces magnetic noise, and facilitates easier manufacturing by allowing for more compact designs and improved phase-to-phase insulation, enhancing the overall efficiency and reliability of the rotary electric machine.
Implementation Method 1
a stator coil including a first group of first and second sets of three-phase windings disposed in part of the slots; a second group of third and fourth sets of three-phase windings disposed in another part of the slots
Data Source
AI summary
In a rotary electric machine, a first group of first and second sets of three-phase windings of a stator coil is disposed in part of substantially circumferentially spaced slots of a stator core, and a second group of third and fourth sets of three-phase windings of the stator coil is disposed in another part of the slots. The first to fourth sets include first to fourth three-phase windings, respectively. Output ends of the first to fourth three-phase windings and input ends of the second and fourth windings are disposed at one of opposing end surface sides of the stator core. The output ends of the first and second three-phase windings of the first and second sets included in the first group are separated from the output ends of the third and fourth three-phase windings of the third and fourth sets included in the second group.