Stator Module Winding Structure for Balanced Slot Potentials
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing wave-winding mode in motor stator modules leads to high production costs, difficulty in manufacturing, and a high risk of breakdown due to voltage differences between layers, resulting in short circuits and motor failure.
Innovation Solution
A stator module design with a specific winding pattern and conductor segments that optimize the placement of lead lines and star point lines at the welding end, preventing loop currents and reducing the risk of motor failure by balancing potential differences between slots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wave-winding mode is used for stator module manufacturing, then production can be achieved with conventional processes, but manufacturing complexity increases and production cost rises due to multiple welding spots and difficult flat wire fastening
Solution Approach 1:
The stator winding is divided into multiple independent coil groups, each occupying a specific slot layer. This segmentation allows for simplified manufacturing of individual coil groups while maintaining the overall winding structure, reducing the complexity of flat wire fastening and welding operations.
Solution Approach 2:
The patent transitions from traditional wave-winding in the radial direction to a layered winding structure where coils are arranged in multiple slot layers (first slot layer, second slot layer, etc.). This dimensional reorganization simplifies the manufacturing process by allowing sequential assembly of coil groups in different layers, reducing the number of welding spots required.
2Quantity of substance
If wave-winding mode is used with multiple slot layers, then winding density increases, but voltage difference between layers causes breakdown and short circuit at high voltage
Solution Approach 1:
The patent connects coil groups across different slot layers through strategic welding arrangements, creating equipotential paths between layers. This reduces voltage differences between the first slot layer, second slot layer, and other layers, preventing electrical breakdown and short circuits while maintaining high winding density.
Solution Approach 2:
Multiple coil groups from different slot layers are electrically connected and mechanically integrated into a unified winding structure. This merging approach maintains high winding density while ensuring proper potential distribution across layers, eliminating the short circuit problem associated with high voltage operation.
3Productivity
If conventional wave-winding is used, then manufacturing can proceed with standard methods, but loop current phenomenon occurs leading to motor failure
Solution Approach 1:
The patent extracts and eliminates the loop current paths that cause motor failure by carefully designing the winding connections between coil groups. The specific arrangement of first winding parts and second winding parts in different slot layers, combined with strategic welding, prevents the formation of closed loops that would generate harmful currents while maintaining manufacturing efficiency.
Solution Approach 2:
The patent converts the potential harmful effect of multiple welding spots into a benefit by strategically positioning welds to create proper electrical connections that prevent loop currents. The welding spots that would normally increase complexity are instead used to establish equipotential connections that eliminate the loop current phenomenon, improving motor reliability.
Data Source
AI summary
A stator module (10) and a motor are provided. The stator module (10) includes a stator core (1) and a stator winding (2). The stator core (1) includes a plurality of stator slots (11), and the plurality of stator slots (11) are distributed in a circumferential direction of the stator core (1). A first winding coil (21) of each phase of the stator winding (2) includes a first winding part (211) and a second winding part (212) connected end to end, the first winding part (211) includes a first crossing segment (2111) to a sixth crossing segment (2116), and the second winding part (212) includes a seventh crossing segment (2121) to a twelfth crossing segment (2126). A second winding coil (22) of each phase of the stator winding (2) includes a third winding part (221) and a fourth winding part (222) connected end to end.