Stator Winding Lead Layout for Balanced Phase Resistance
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Solution Overview
Problem
The existing motor designs face challenges in miniaturization and performance due to uneven distribution of lead wires and neutral wires, leading to unbalanced resistance and current in each phase, which affects the motor's stability and efficiency, and also complicates the connection and arrangement of electrical gaps.
Innovation Solution
A stator assembly with lead wire ends uniformly distributed on the radial inner side, allowing for a balanced star point connection or delta connection method, which balances the resistance and current in each phase, and facilitates better wiring connections by positioning the neutral connecting plate on the radial inner side to optimize space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If lead wire ends and neutral wire ends are arranged on the radial outer side for ease of connection with motor controller, then connection convenience is improved, but motor miniaturization is hindered and phase resistance balance deteriorates
Solution Approach 1:
The patent inverts the conventional arrangement by moving lead wire ends and neutral wire ends from the radial outer side to the radial inner side of the stator winding. This inversion enables better space utilization for motor miniaturization while maintaining connection convenience through optimized wiring paths that route wires axially to the motor controller.
Solution Approach 2:
The patent transitions the wire arrangement from a radial configuration to an axial configuration. By leading wires out axially from the radial inner side rather than radially from the outer side, the patent creates a three-dimensional wiring path that optimizes both compactness and connection accessibility.
2Ease of manufacture
If lead wire ends are collectively led out from radial outer side, then connection process is simplified, but phase resistance balance deteriorates due to uneven distribution
Solution Approach 1:
The patent applies local quality by uniformly distributing lead wire ends across different angular positions on the radial inner side rather than collecting them at one location. Each phase's wire ends are positioned at specific angular intervals, ensuring equal electrical path lengths and balanced phase resistance while maintaining manufacturing simplicity through standardized positioning.
3Ease of operation
If neutral wire connection ends are arranged towards axial outer side to facilitate welding, then welding convenience is improved, but electrical gap arrangement compliance deteriorates
Solution Approach 1:
The patent inverts the axial arrangement direction by positioning neutral wire connection ends toward the axial inner side rather than the outer side. This inversion maintains welding accessibility while ensuring proper electrical gap compliance by positioning connection ends within the stator assembly boundaries.
Data Source
AI summary
The disclosure provides a stator assembly, a motor, a powertrain and a vehicle, the stator assembly includes a stator core and a stator winding, the stator core is provided with a plurality of stator slots, the plurality of stator slots are distributed along a circumferential direction of the stator core, a winding part of one winding wire of each phase of the stator winding is arranged in the plurality of stator slots, a leading-out end of one winding wire of each phase is located on a radial inner side of the winding part based on the stator core, and the leading-out end of one winding wire of each phase is uniformly distributed along the circumferential direction of the stator core.