Stator Assemblies with Continuous Delta Windings
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Solution Overview
Problem
Current stator assemblies for three-phase dynamoelectric machines face challenges in efficiently routing and connecting winding wires due to complex configurations and the need for precise phase connections, leading to increased complexity and potential for errors in assembly.
Innovation Solution
A stator assembly with a non-segmented stator core and teeth extending towards a central opening, featuring coil portions electrically coupled in a delta winding pattern, with continuous lengths of winding wire defining both coil and connection portions, and end caps that guide and separate connection portions by phase to prevent shorting, allowing for simplified and efficient winding and connection processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional winding methods with separate wire ends are used for each coil, then each coil can be independently formed around teeth, but the complexity of routing and connecting wire ends to proper phases increases significantly
Solution Approach 1:
The patent merges the connection portions with the coil portions by forming them from a single continuous length of winding wire. This integration eliminates the need for separate routing and connection of individual wire ends, as the connection portions are inherently created during the coil winding process itself, thereby reducing manufacturing complexity while maintaining ease of winding.
Solution Approach 2:
The patent implements preliminary action by pre-configuring the stator core with guide surfaces and grooves that direct the winding wire along the desired path before the actual winding occurs. These pre-formed structural features guide the wire ends to the correct phases automatically, eliminating complex post-winding routing operations and reducing the overall complexity of the manufacturing process.
2Reliability
If multiple wire ends are routed and bundled for connecting to power source with different phases, then proper phase connections can be achieved, but the potential for assembly errors increases
Solution Approach 1:
The stator core is pre-equipped with guide surfaces and grooves that define the exact path for wire routing before winding begins. These pre-formed guides ensure that wire ends automatically reach the correct phase connection points, eliminating human error in phase assignment and significantly improving connection reliability while reducing the complexity of the routing process.
Solution Approach 2:
The guide surfaces and grooves act as intermediaries between the winding process and the phase connection requirements. They mediate the routing of wire ends by physically directing them to the appropriate phases, thereby ensuring accurate connections without requiring complex manual routing and bundling operations that could introduce errors.
3Productivity
If continuous length of winding wire is used to define both coil portions and connection portions, then the winding process is simplified and manual intervention is reduced, but the wire routing path becomes more complex
Solution Approach 1:
The stator core structure includes pre-formed guide surfaces and grooves that define the complex wire routing path before winding begins. By preparing these guiding features in advance, the patent enables the use of continuous winding wire to form both coil and connection portions in an automated manner, thereby simplifying the actual winding process and improving productivity despite the inherent complexity of the routing path.
Solution Approach 2:
The continuous winding wire serves itself by being automatically guided through the complex routing path defined by the stator core's guide surfaces and grooves. The wire forms both coil portions and connection portions without requiring external intervention or separate operations, enabling automated winding and significantly improving productivity while the pre-formed guides manage the routing complexity.
Data Source
AI summary
According to some aspects of the present disclosure, example stator assemblies for three phase dynamoelectric machines and related winding methods are disclosed. An example stator assembly generally includes a non-segmented stator core including a stator yoke and a plurality of teeth. The stator assembly also includes a plurality of coil portions electrically coupled in a delta winding pattern, and including a first coil portion extending around a first one of the plurality of teeth and a second coil portion extending around a second one of the plurality of teeth. The stator assembly further includes a plurality of connection portions including a first connection portion extending between the first coil portion and the second coil portion and electrically coupling the first coil portion and the second coil portion. The first coil portion, the second coil portion and the first connection portion are defined by a continuous length of winding wire.