Stator Module Radial Size Reduction via Axial Phase End Integration
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Solution Overview
Problem
The existing stator modules for electric motors, particularly in motor vehicles, face limitations due to the protrusion of phase ends and winding components beyond the outer periphery of the stator laminated core, which restricts the motor diameter and hence the power output, as conventional winding methods and contact arrangements are not optimized for space efficiency.
Innovation Solution
A stator module design featuring a stator laminated core with inwardly directed stator teeth and a rotating-field winding where an annular cover is used to contain the phase ends axially within the stator laminated core's periphery, eliminating radial protrusion and allowing for a more compact design by integrating insulation-displacement contacts on the annular cover for efficient phase end connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional winding methods with laying rings and terminations are used, then the rotating-field winding can be properly guided and connected, but the phase ends and contact elements protrude radially beyond the stator laminated core, increasing the motor diameter
Solution Approach 1:
The patent repositions the phase ends and contact elements from a radial arrangement to an axial arrangement. The laying ring with integrated contact elements is positioned at the axial end face of the stator laminated core, allowing phase ends to be contacted axially rather than radially. This dimensional change eliminates the need for radial protrusion and collar structures, reducing motor diameter while maintaining manufacturing feasibility.
2Length of stationary object
If the motor diameter is reduced to eliminate the collar, then space utilization is improved, but the phase ends and contact elements cannot be properly arranged outside the stator periphery
Solution Approach 1:
The patent merges the contact elements with the laying ring structure, integrating the function of guiding phase ends and providing electrical contact into a single axial component. The contact elements are positioned on the axial end face of the laying ring, combining previously separate functions (winding guidance and electrical contact) into one integrated structure, enabling compact radial design while maintaining connection capability.
Solution Approach 2:
The laying ring with pre-positioned contact elements is installed on the stator laminated core before the winding process. This preliminary arrangement of contact elements at the axial end face guides the winding process and ensures proper phase end positioning, eliminating the need for subsequent radial adjustments or collar structures.
3Reliability
If insulation-displacement contacts are used for phase end connection, then electrical connection efficiency is improved, but the contact elements require space outside the winding region
Solution Approach 1:
The patent positions the insulation-displacement contact elements on the axial end face of the laying ring rather than in the radial direction. This axial positioning allows the contact elements to access phase ends without requiring additional radial space beyond the stator periphery, eliminating the need for collar structures while maintaining reliable electrical connection.
Data Source
AI summary
A stator module for an electric motor has a stator laminated core with a number of inwardly directed stator teeth and a rotating-field winding with a plurality of phases arranged on the stator teeth. The rotating-field winding has at least one coil per phase, which coil is electrically connected to a first phase end and a second phase end. A laying ring is placed onto the stator laminated core at the end face and surrounds the stator teeth as coil body in order to guide the rotating-field winding. An annular cover is placed onto the laying ring at the end face, on which cover each of the phase ends is contacted with one of the phase ends of another phase, in such a way that the entire rotating-field winding does not protrude radially externally beyond an outer periphery of the stator laminated core.