Compact Stator Assembly with Low End-Turn Height
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Solution Overview
Problem
Electric machines with distributed stator windings face challenges in achieving a reduced end-turn height to save space while maintaining desirable performance characteristics and minimizing acoustic noise.
Innovation Solution
The design incorporates a stator assembly with distributed windings that have an end turn height ratio of less than or equal to 0.07 to the outside diameter, allowing for a compact configuration and reduced acoustic noise, featuring a stator core with longitudinally extending slots and end turn portions optimized for a low-profile stator assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If distributed windings are used, then acoustic noise is reduced and performance is improved, but end-turn height increases
Solution Approach 1:
The patent transitions from conventional distributed windings with large end-turn heights to a planar winding configuration where conductors are arranged in a two-dimensional plane at the stator periphery. This dimensional change allows the windings to achieve the acoustic noise reduction benefits of distributed windings while maintaining a compact end-turn height profile, as the conductors spread out laterally rather than extending axially.
Solution Approach 2:
The patent modifies the geometric parameters of the winding configuration by constraining the end-turn height ratio to be less than or equal to 0.07 times the stator outside diameter. This parameter change forces a reconfiguration of the winding layout from a three-dimensional extended structure to a compressed planar arrangement, thereby reducing end-turn height while preserving the distributed winding topology that reduces acoustic noise.
2Length of stationary object
If concentrated windings are used, then end-turn height is reduced, but acoustic noise increases and slot fill decreases
Solution Approach 1:
The patent applies planar geometry to the winding arrangement, causing conductors to distribute themselves across a two-dimensional surface at the stator periphery rather than concentrating in discrete axial positions. This dimensional transformation enables the windings to achieve low end-turn heights similar to concentrated windings while simultaneously obtaining the acoustic noise reduction benefits characteristic of distributed windings.
Solution Approach 2:
The patent creates local variations in conductor distribution by arranging different phases and poles in specific planar patterns around the stator circumference. This local quality differentiation allows each region to be optimized for both compact height and noise reduction, with conductors positioned to minimize acoustic radiation while maintaining space efficiency.
Data Source
AI summary
A stator assembly (50) includes a stator core (52) defining an outside diameter (OD) and an inside diameter (ID) with longitudinally extending slots (58) formed between the inside diameter and the outside diameter. The stator core (52) defines a core height extending longitudinally from a first end (53) to a second end (55) of the stator core (52). Distributed windings (60) are retained by the stator core (52) and include an in-slot portion (66) positioned in the slots of the stator core (52), a first end turn portion (62) adjacent to the first end (53) of the stator core, and a second end turn portion (64) adjacent to a second end (55) of the stator core. The first end turn portion (62) defines a first end turn height (h1) extending from the first end (53) of the stator core to a vertex (78) of the first end turn portion (62). A ratio of the first end turn height (h1) to the outside diameter (OD) of the stator core is less than or equal to 0.07.