Axial Flux Stator Conductor Layout for Compact Distributed Windings
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Solution Overview
Problem
Radial flux machines have limited efficiency across varying operating conditions and require additional components like transmission units to optimize performance, while axial flux machines with single-tooth windings suffer from high harmonic content affecting efficiency and acoustics, and those with distributed windings have increased installation space requirements.
Innovation Solution
A stator design for axial flux machines featuring a stator body with circumferentially arranged teeth and grooves, where conductor pairs form windings by meandering radially and enlacing stator teeth, allowing for efficient current flow and reduced winding head volume, enabling high power density and efficiency with minimal installation space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If distributed windings are used in axial flux machines, then the harmonic content is reduced and efficiency is improved, but the winding heads require more installation space in the axial and radial directions
Solution Approach 1:
The patent transitions from conventional planar winding arrangements to a three-dimensional configuration where conductors are arranged in multiple layers within grooves. The conductors are positioned at different radial distances from the stator center, creating a layered structure that reduces the axial and radial footprint of winding heads while maintaining distributed winding benefits for harmonic reduction
Solution Approach 2:
The patent embeds conductors within grooves formed in the stator teeth, nesting the winding structure within the existing stator geometry. This nesting approach allows the winding heads to be contained within the grooves rather than extending outward, significantly reducing the required installation space while preserving the distributed winding configuration
2Force
If the maximum diameter of active components is increased in axial flux machines, then the maximum torque is increased, but the winding heads require larger radial expansion space
Solution Approach 1:
The patent utilizes the axial dimension by arranging conductors in multiple layers at different radial positions within grooves. This three-dimensional arrangement allows the active components to achieve larger effective diameters for increased torque without requiring proportional increases in radial installation space, as the conductors are stacked axially rather than expanding radially
3Loss of energy
If radial flux machines are designed for a single operating point, then the degree of efficiency is maximized at that point, but the machine cannot adapt to changing requirements and operating parameters
Solution Approach 1:
The patent employs power electronic converters that can dynamically adjust the operating parameters of the axial flux machine, including switching between different winding configurations and adjusting excitation levels. This dynamic control capability allows the machine to adapt to varying operating requirements while maintaining high efficiency across a broad operating range, overcoming the static nature of conventional radial flux machines
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
The stator design achieves high power density and efficiency with reduced installation space requirements, addressing the limitations of radial flux machines and axial flux machines with single-tooth windings by optimizing winding configuration and current flow.
Implementation Method 1
conductor sections of at least one conductor pair which forms at least a portion of windings of the stator
Implementation Method 2
enlace around one group of stator teeth
Data Source
AI summary
A stator for a rotary electric machine, a method for producing the stator, and the rotary electric machine. The stator has a body with a plurality of stator teeth arranged in a circumferential direction; grooves between the stator teeth; and conductor sections, arranged in the grooves, of at least one conductor pair which forms at least a portion of windings. In each groove, conductor sections are arranged along the groove depth parallel to and offset from one another and the sequence of the arrangement of the parallel conductor sections in each groove alternates in the circumferential direction. The conductors of the conductor pair, deviating from a winding direction extending basically circumferentially, meander in a radial direction, and via an enlacement formed thereby in each case, enlace around one group of stator teeth. The stator enables a high power density and a high degree of efficiency along with low installation space requirements.