Stator Winding Layout With Helical Paths for Flexible Interconnection
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Solution Overview
Problem
Stators for electric machines lack flexibility in interconnection options and are not suitable for high-volume production with low costs, as existing designs are relatively inflexible and limited in manufacturing scalability.
Innovation Solution
A stator design featuring a hollow-cylindrical laminated core with multiple receiving grooves and electric conductor sections forming a stator winding with multiple layers, allowing for flexible interconnection options through helical current paths and versatile loop windings using forming-rod conductors, enabling high-volume production and cost reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wave windings with meandering current path are used, then the stator winding structure is established, but flexibility in interconnection options is limited
Solution Approach 1:
The stator winding is divided into multiple independent conductor sections that can be individually connected in series or parallel configurations. Each conductor section is a discrete unit that can be selectively interconnected to create different winding patterns, part-windings, and connection topologies, providing flexibility without increasing overall structural complexity
Solution Approach 2:
The conductor sections are designed with universal connection capabilities at their ends, allowing them to be interconnected in multiple configurations (series, parallel, part-windings) to serve different functional requirements. The same basic conductor section structure can adapt to various winding specifications and interconnection needs
2Adaptability or versatility
If tooth-coil windings with flexible winding wire are used, then interconnection flexibility is improved, but suitability for high-volume production decreases
Solution Approach 1:
Conductor sections are pre-formed with precise geometries and pre-equipped with connection elements at their ends before assembly. This preliminary preparation of conductor sections enables automated assembly processes in high-volume production while maintaining the flexibility of discrete interconnection options
Solution Approach 2:
The winding is segmented into standardized conductor sections that can be independently manufactured and then automatically assembled. This segmentation enables modular production approaches where conductor sections can be prepared in advance and quickly assembled, improving productivity while preserving interconnection flexibility
3Ease of manufacture
If conventional stator windings are used, then basic electrical function is achieved, but manufacturing cost reduction is limited
Solution Approach 1:
Conductor sections are pre-formed with precise geometries and connection elements before assembly into the stator. This preliminary preparation enables automated assembly processes, reducing labor costs and improving manufacturing efficiency while maintaining quality consistency across high-volume production
Solution Approach 2:
The conductor sections are designed with self-aligning and self-connecting features that reduce the complexity of assembly operations. The standardized connection elements at conductor section ends enable automated connection processes, lowering manufacturing costs and improving productivity through reduced assembly time and complexity
Data Source
AI summary
The invention relates to a stator (1) for an electric machine, comprising an essentially hollow-cylindrical laminated core (2) with multiple receiving grooves (4) which are arranged distributed. Multiple electric conductor sections (La, Lb) per receiving groove (4) formed by forming rods form a stator winding (14) with at least two part-windings (TWa, TWb). The at least two electric part-windings (TWa, TWb) are respectively formed by at least one first and one second electrically series-connected winding segment (WSa, WSb), wherein conductor sections (La, Lb) of the first winding segment (WSa) are electrically interconnected by means of first and second electric connecting sections (VBa, VBb) such that a helical current path (17a) is defined along a first radial direction (18a) to the longitudinal axis (3) of the laminated core (2) and conductor sections (La, Lb) of the second winding segment (WSb) are electrically interconnected by means of first and second electric connecting sections (VB a, VBb) such that a second helical current path (17b) is defined along an opposite, second radial direction (18b) to the longitudinal axis (3) of the laminated core (2).