Stator Crossover Wire Separation for Motor Reliability
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Solution Overview
Problem
Conventional concentrated winding motors face issues with crossover wires of different phases potentially contacting each other, leading to reliability and lifespan concerns.
Innovation Solution
A stator design featuring separate crossover wire guides and winding units for each phase, with insulators and recesses in the yoke to securely position and separate the phases, preventing contact between crossover wires of different phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If in-phase winding wires are arranged on every other tooth in concentrated winding motors, then winding density and motor efficiency are improved, but crossover wires of different phases may contact each other causing reliability issues
Solution Approach 1:
The stator is divided into multiple tooth units, each independently equipped with crossover wire guides. This segmentation allows each tooth unit to manage its own crossover wires separately, preventing contact between different phase wires while maintaining concentrated winding density.
Solution Approach 2:
Crossover wire guides are introduced as intermediary structures between winding wires of different phases. These guides act as mediators that physically separate and guide the crossover wires, preventing direct contact between different phase wires while allowing the concentrated winding arrangement to be maintained.
2Reliability
If separate crossover wire guides are provided for each phase, then reliability is improved by preventing wire contact, but device complexity increases
Solution Approach 1:
Multiple tooth units with their own crossover wire guides are merged into a single integrated stator structure. The guides are positioned and configured to work together as a unified system, reducing overall complexity while maintaining the reliability benefits of separate phase wire guidance.
Solution Approach 2:
The crossover wire guides are designed with universal functionality to handle multiple phases and configurations. Each guide structure serves multiple purposes: guiding crossover wires, providing insulation, and maintaining structural integrity, thereby reducing the need for additional specialized components.
Data Source
AI summary
A stator includes a first teeth unit including a first insulator having an annular first crossover wire guide and a plurality of first winding units radially provided at regular intervals on an outer circumference of the first crossover wire guide to cover teeth of one phase group of an alternating current, the teeth of the one phase group having upper halves fitted to the first winding units, a third insulator that covers lower halves of the teeth, and a winding wire of one phase wound around the teeth of the one phase group, a second teeth unit having an identical configuration to that of the first teeth unit in which a winding wire of the other phase is wound in a concentrated manner, with second winding units inserted between adjacent ones of the first winding units, and an annular yoke including a plurality of recesses at regular intervals.