Concentrated Flat-Wire Stator Structure for Higher Slot Fill
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Solution Overview
Problem
Existing motor stator winding technologies face challenges in achieving a high slot fill factor, particularly with distributed windings and parallel slot structures, which require complex equipment and result in low fill efficiency.
Innovation Solution
A stator structure with a concentrated winding of flat wires on the stator teeth, arranged in multiple layers, where the number of wires in each layer is optimized to reduce intersections and maximize slot fill factor, incorporating a stator core with a specific tooth geometry and insulation to enhance winding regularity and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If distributed windings and parallel slot structures are used, then the motor can be manufactured, but the slot fill factor is low and the equipment becomes complex
Solution Approach 1:
The patent changes the winding parameters by using concentrated windings instead of distributed windings, and uses flat wires instead of round wires. The tooth geometry parameters are also optimized with specific width ratios (t2/t1 between 1.0 and 1.5) to maximize the slot fill factor while maintaining manufacturability.
Solution Approach 2:
The stator tooth cross-section is designed with asymmetric width distribution, where the tooth width varies along the radial direction. The tooth body has width 2×t1 at the top and 2×t2 at the bottom, creating an asymmetric geometry that optimizes space utilization for the concentrated flat wire windings.
2Extent of automation
If concentrated winding is used, then automatic winding is facilitated, but the slot fill factor is relatively low
Solution Approach 1:
The patent uses composite construction by combining concentrated winding topology with flat wire conductors. This composite approach leverages the advantages of both concentrated windings (ease of automation) and flat wires (high slot fill factor), achieving a slot fill factor exceeding 50% while maintaining automatic winding capability.
Solution Approach 2:
The patent transitions from traditional round wires to flat wires, adding a dimensional change in the conductor cross-section. This dimensional change allows the wires to be packed more efficiently in the slot, significantly increasing the slot fill factor while maintaining the concentrated winding structure for automated manufacturing.
3Quantity of substance
If multiple layers of flat wires are wound on stator teeth, then the slot fill factor improves, but the probability of winding intersection increases
Solution Approach 1:
The patent segments the winding into multiple layers with different numbers of parallel wires in each layer. The first layer has a different number of wires than the second layer, creating a segmented structure that reduces intersections. Additionally, the stator teeth are segmented into tooth bodies and tooth boots, with windings distributed across both segments.
Solution Approach 2:
Different layers of the winding have different local qualities in terms of the number of parallel wires. The first layer and second layer are designed with different wire counts, allowing optimization of each layer's contribution to the magnetic field while minimizing intersections. The tooth body and tooth boot also have different local geometries to accommodate the multi-layer winding structure.
Data Source
AI summary
A stator structure, a motor, and electrical equipment are provided. The stator structure includes a stator core that includes a stator yoke and multiple stator teeth. The stator teeth are arranged on the stator yoke. A stator slot is formed between two adjacent stator teeth. Each stator tooth includes a tooth body and a tooth boot. The tooth body is arranged on the stator yoke. The tooth boot is arranged on the tooth body. The stator structure further includes a winding arranged on the stator teeth. The winding includes flat wires wound on the stator teeth in a concentrated manner. The flat wires is wound on the stator teeth in multiple layers. The number of flat wires in the layer of the winding away from the stator teeth is not more than the number of flat wires in the layer of the winding close to the stator teeth.