Stator Crossover Wire Routing for Reduced Axial Height
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Solution Overview
Problem
Conventional stators with crossover wires routed parallel to the axis require increased axial height of the wall section when multiple sets of neighboring slot portions are wound, leading to a larger stator size.
Innovation Solution
Routing crossover wires obliquely on the outer peripheral surface of the insulator's wall section, with pull-out and pull-in portions at neighboring stages, reduces the axial height of the wall section, allowing for a smaller stator size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If crossover wires are routed parallel to the axis on the outer peripheral surface of the wall section, then the routing is simple and easy to manufacture, but the axial height of the wall section increases when multiple sets of neighboring slot portions are wound
Solution Approach 1:
The patent changes the routing direction of crossover wires from a horizontal path (parallel to the axis) to an oblique path that combines both horizontal and vertical components. This dimensional change allows multiple crossover wires to be arranged more compactly in the axial direction, reducing the wall section height while maintaining manufacturability through systematic routing patterns.
Solution Approach 2:
The patent introduces flexibility in the routing approach by allowing crossover wires to be routed at oblique angles rather than strictly parallel to the axis. This dynamic routing strategy enables adaptation to different winding configurations and slot arrangements, optimizing the axial height based on specific design requirements while maintaining ease of manufacture.
2Reliability
If the axial height of the wall section is increased to accommodate multiple crossover wires, then the stator can be made larger, but the overall size of the motor and compressor increases
Solution Approach 1:
By routing crossover wires obliquely across the wall section surface rather than parallel to the axis, the patent utilizes both horizontal and vertical dimensions more efficiently. This allows multiple wires to be accommodated within a reduced axial height, thereby reducing the overall stator volume while maintaining adequate space for all necessary crossover connections.
Solution Approach 2:
The patent changes the routing angle parameter of crossover wires from 0 degrees (parallel to axis) to oblique angles. This parameter change optimizes the spatial arrangement of crossover wires, allowing them to fit within a compact axial height while maintaining proper spacing and connection points, thus reducing the overall stator dimensions.
3Productivity
If multiple sets of neighboring slot portions are wound simultaneously, then the winding efficiency increases, but the number of crossover wires to be routed increases, requiring greater axial height
Solution Approach 1:
The oblique routing approach distributes crossover wires across both horizontal and vertical dimensions, allowing multiple wires from simultaneously wound slot sets to be arranged in a staggered pattern. This reduces the concentration of wires in the axial direction, enabling high winding efficiency while maintaining a compact axial height.
Solution Approach 2:
The flexible oblique routing strategy adapts to the increased number of crossover wires from simultaneous winding operations. By adjusting the routing angle and pattern, the system can accommodate varying numbers of wires while maintaining consistent axial height, thus supporting high productivity without proportionally increasing dimensions.
Data Source
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AI summary
A stator is provided in which the height of a wall section of an insulator is reduced. Crossover wires (50a to 50c) of coils (50) are routed on an outer peripheral surface of a wall section (57) of an insulator (51) so as to extend, when viewed in a direction orthogonal to an axis of the stator, in a direction oblique to a plane orthogonal to the axis.