Stator Lead Wire Layering for Electric Machine Size
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Solution Overview
Problem
Existing electric machine designs face challenges in achieving a compact and efficient structure with reduced size and increased efficiency, while also simplifying manufacturing processes, due to varying end turn heights and complex lead wire management.
Innovation Solution
The design features a stator with a plurality of lead wires extending from a common winding layer, where each phase includes multiple windings distributed across different radial layers, allowing for efficient manufacturing and reduced size through balanced winding patterns and phase shifting, which simplifies the manufacturing process and reduces wire end height variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If windings are inserted into slots of laminations with varying end turn heights, then the electric machine achieves compact structure, but the manufacturing complexity increases due to handling difficulties
Solution Approach 1:
The patent applies local quality by positioning lead wires specifically in the radially outermost layer where they are most accessible, while other windings occupy inner layers. This localized arrangement optimizes the specific region for manufacturing operations without compromising the overall compact structure, allowing easier handling of lead wires while maintaining reduced machine size.
2Ease of manufacture
If lead wires are positioned in radially outermost layer, then ease of handling and manufacturing is improved, but the winding space utilization may be reduced
Solution Approach 1:
The patent segments the winding structure into distinct radial layers, with lead wires confined to the radially outermost layer and other windings in inner layers. This segmentation allows the lead wire region to be optimized for manufacturing accessibility while the inner layers maximize space utilization for functional windings, resolving the conflict between ease of handling and space efficiency.
3Productivity
If all windings have different lengths to equalize end turn heights, then manufacturing efficiency improves, but wire material usage increases
Solution Approach 1:
The patent changes the parameter of lead wire placement from distributed across multiple layers to concentrated in the radially outermost layer. This parameter change allows the use of shorter, more efficient wire lengths while achieving equalized end turn heights, thereby improving manufacturing efficiency without excessive wire material consumption.
Data Source
AI summary
An electric machine with a stator operably coupled with a rotor. The stator includes a stator core defining a plurality of slots. Each of the slots defines a plurality of layer positions located at different radial distances from a rotational axis of the electric machine. At least three windings are associated with each of the phases of the machine. In a first slot, a first winding is disposed in a first layer position. A second winding is disposed in a second layer position. A third winding is disposed in a third layer position. The first winding includes a first outside lead wire extending from the first slot. The second winding includes a second outside lead wire extending from a second slot. The third winding includes a third outside lead wire extending from a third slot. Each of the outside lead wires are in the first layer position.