Stator End Winding Beveling for Compact Generator Design
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Solution Overview
Problem
In electrical machines with a high number of poles and small pole pitch, double-layer windings are difficult to mount and require significant space for end windings, leading to inefficient material use and increased weight.
Innovation Solution
The stator element features end windings with beveled or curved shapes, differing in axial length, which reduces the axial dimensions and allows for a more compact and densely packed design, using materials like copper or aluminum, and can be tilted to further optimize space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If double-layer windings are used in electrical machines with high number of poles and small pole pitch, then all stator windings are identical and easy to manufacture, but the insertion of the last stator winding requires removal of the first stator winding and significant space is required for end windings
Solution Approach 1:
The stator windings are divided into multiple independent single-layer windings instead of using double-layer windings. Each winding can be inserted independently into the slots without requiring removal of other windings, eliminating the assembly complexity while maintaining manufacturing simplicity through standardized single-layer construction
Solution Approach 2:
The end windings are configured to extend in different spatial directions and arrangements. By optimizing the spatial positioning and dimensional configuration of end windings from multiple stator windings, the available space is utilized more efficiently, reducing the overall axial length requirement while accommodating all necessary windings
2Ease of operation
If single-layer windings are used to avoid removal of first winding and eliminate segment joint crossing, then mounting difficulty is reduced, but large end windings take up much space and require huge amounts of copper
Solution Approach 1:
Multiple single-layer stator windings are combined in a coordinated arrangement where their end windings are positioned and oriented to utilize the same spatial region. This merging approach allows the end windings to share space rather than requiring separate dedicated spaces, reducing both the total volume occupied and the amount of copper material needed
Solution Approach 2:
The configuration parameters of the end windings are optimized by varying their spatial arrangement, orientation angles, and dimensional proportions. By adjusting these parameters, the end windings achieve a compact configuration that minimizes material usage while maintaining electrical performance and ease of mounting
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Stator element (1) for an electrical machine, particularly a generator, especially a generator for a wind turbine, particularly a direct drive wind turbine, comprising a yoke (2) having at least two adjacently disposed axially extending slots (3) for accommodating at least one stator winding (4, 5, 6), the stator winding (4, 5, 6) being built of a number of strands (7) stacked on top of each other in radial direction, with each stator winding (4, 5, 6) comprising end windings (4', 5', 6') axially extending off the yoke (2), wherein the strands (7) of the respective stator winding (4, 5, 6) differ in their axial lengths with at least one end winding (4', 5', 6') of a respective stator winding (4, 5, 6) having a bevelled or curved shape.