Stator Diamond Coil Layout With Fewer Series Connections
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Solution Overview
Problem
Existing stator winding arrangements with diamond-shaped coils require numerous long connections between poles and many welds, which are difficult to complete and can lead to imbalanced windings and lower slots per pole per phase counts.
Innovation Solution
A stator winding arrangement with diamond coils that includes parallel paths formed by pairs of adjacent coils connected in series, using extended coil connections to reduce the number of long series connections and welds, and arranging coils in specific layers within slots to achieve balanced windings with high slots per pole per phase counts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If diamond-shaped coils are positioned in adjacent slots, then the winding arrangement can achieve high slots per pole per phase count, but the number of long series connections between poles increases significantly
Solution Approach 1:
The winding arrangement is divided into multiple parallel paths (at least three per phase) instead of a single continuous path. This segmentation allows coils in adjacent slots to be distributed across different parallel paths, reducing the need for long series connections between poles while maintaining high slots per pole per phase count.
2Ease of manufacture
If coils in adjacent slots are connected in series, then the winding arrangement can be completed, but the number of welds increases and becomes difficult to manage
Solution Approach 1:
By segmenting the winding into multiple parallel paths, the total number of series connections required is reduced. Each parallel path contains fewer coils connected in series, which directly reduces the number of welds needed while still achieving complete winding coverage.
Solution Approach 2:
The patent introduces intermediate connection points and distributed winding paths that act as mediators between coils in adjacent slots. This allows for more manageable connection sequences and reduces the complexity of welding operations by breaking down the continuous series connection chain into smaller, more manageable segments.
3Ease of manufacture
If multiple long series connections are used between poles, then all coils can be connected, but the winding arrangement becomes unbalanced and complex
Solution Approach 1:
Dividing the winding into multiple parallel paths creates a more balanced distribution of coils across poles. Each parallel path can be carefully designed to maintain symmetry and balance, preventing the unbalanced composition that arises from single long series connections spanning multiple poles.
Data Source
AI summary
A stator for an electric machine includes a winding arrangement including a plurality of parallel paths. Each parallel path includes a plurality of coils arranged on the core, each coil defined by coil legs and end turns, the coil legs including left legs and right legs extending through the slots of the core and arranged in layers within the slots. The left legs and right legs of each coil are connected by first end turns at one end of the core and second end turns at an opposite end of the core. The plurality of coils of each parallel path include a first pair of adjacent coils connected in series and a second pair of adjacent coils connected in series. Additionally, an extended coil connection connects the first pair of adjacent coils and the second pair of adjacent coils in series.