Stator End Winding Layout Without Lead Bends for Lower Vibration
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Solution Overview
Problem
The existing end winding arrangements in electro-mechanical devices, such as electric generators, are bulky and costly due to long involute members, which cause vibration issues, require complex mechanical support, and increase manufacturing complexities, leading to increased costs and design challenges.
Innovation Solution
The end winding arrangement features stator bars with a unitary involute member extending from the cell bend member, eliminating the lead bend section, and utilizing a non-twisted connector member to interconnect conductors, reducing the overall length of the stator bar and simplifying the mechanical support structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If long involute members are used in stator bars, then the stator can accommodate conductors and provide structural support, but the overall length of the stator bar increases making the device bulkier
Solution Approach 1:
The stator bar is segmented into distinct functional portions: a linear portion for structural support, an involute portion for conductor accommodation, and a cell bend portion for connection. This segmentation allows each portion to be optimized independently, reducing the overall length while maintaining functionality and reducing vibration issues.
2Quantity of substance
If long involute members are used in stator bars, then conductor accommodation is ensured, but complex mechanical support structures are required
Solution Approach 1:
The linear portion, involute portion, and cell bend portion are merged into a single integrated stator bar structure formed from one continuous piece of conductive material. This eliminates the need for separate auxiliary connection elements and complex mechanical support structures, simplifying both the design and manufacturing while reducing material quantity.
3Ease of manufacture
If long involute members are used in stator bars, then conductor connection is enabled, but manufacturing complexities increase
Solution Approach 1:
The stator bar is pre-formed as a single integrated structure with the linear portion, involute portion, and cell bend portion already configured in the correct geometry. This preliminary formation eliminates the need for complex assembly operations and reduces rewound time, as the bar requires no further shaping or connection operations during manufacturing.
Data Source
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AI summary
An end winding arrangement (300) of a stator (601) of an electro-mechanical device (600) is provided. The end winding arrangement (300) includes at least two stator bars (201) each having a linear member (103) and a cell bend member (105). Each of the at least two stator bars (201) is configured to have a unitary involute member (301) extending from each cell bend member (105) such that the involute member (301) is configured as a single involute section (104A) without a lead bend section (104B) for reducing vibrations in the electro-mechanical device (600) .