Stator Core Winding with Continuous Conductor
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Solution Overview
Problem
The existing methods for winding stator cores with round wire result in twisting issues and require a large number of connections, especially in multi-pole systems, leading to inefficiencies and increased complexity.
Innovation Solution
A stator design featuring a body with an outer and inner portion, where a continuous conductor is wound around select stator teeth to form poles with fewer twists than wraps, reducing bulk and enabling efficient connections through a compact form factor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If round wire is wound around stator teeth using a rotating winding needle, then the stator core can be efficiently wound, but the wire twists as a result of the rotation created when wrapping the stator tooth
Solution Approach 1:
The stator core is divided into multiple individual stator teeth that are wound separately and then joined together to form poles. This segmentation allows each tooth to be wound independently, reducing the twisting effect on the wire while maintaining winding efficiency.
Solution Approach 2:
The patent transitions from winding wire in a three-dimensional rotating motion around individual teeth to a planar winding process where the wire is wound in a two-dimensional manner across the stator teeth, thereby reducing the twisting effect caused by rotation.
2Productivity
If multiple wires are simultaneously wound around a tooth and then connected to a main bus, then the winding process can be completed, but a large number of final connections are required
Solution Approach 1:
Multiple individual stator teeth are joined together to form consolidated poles, merging multiple connection points into fewer pole connections. This reduces the total number of connections required while maintaining the productivity benefits of simultaneous winding.
Solution Approach 2:
The patent creates a universal pole structure that can accommodate multiple wires from different teeth, allowing a single pole connection to serve multiple winding functions. This multi-functionality reduces the overall number of connections needed in the system.
3Shape
If individually wound stator teeth are joined together to form poles, then wire twisting is avoided, but as many as 96 connections are required for a 24 pole stator
Solution Approach 1:
The patent merges multiple individually wound stator teeth into consolidated poles, combining several connection points into a single pole assembly. This merging process maintains the wire twist reduction benefit of individual winding while reducing the total connection count from 96 to a more manageable number.
Solution Approach 2:
The stator teeth are pre-wound individually with proper wire orientation before being assembled into pole structures. This preliminary winding action ensures minimal twisting is introduced during the assembly process, and the pre-prepared teeth can be connected more efficiently in groups rather than one at a time.
Data Source
AI summary
A stator includes a body portion having an outer portion and an inner portion that defines an interior region, a plurality of stator teeth members extending from the inner portion into the interior region, and at least one continuous conductor wound around select ones of the plurality of stator teeth members to form at least one pole. Each of the plurality of stator teeth members including a number of wraps of the at least one continuous conductor. The at least one continuous conductor including a number of twists that is fewer than the number of wraps.