Electrical Machine Stator Radial Conductor Interlocking
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Solution Overview
Problem
Conventional stators and rotors produced using plug-in technology have limitations in achieving a compact end winding height, which affects the active lamination length and installation space, thereby impacting the efficiency and power-to-length ratio of electrical machines.
Innovation Solution
The stator or rotor design incorporates conductor ends that are twisted into inner and outer winding space parts radially, allowing for a more compact packing and reduced overall length, with the conductor ends being arranged in a staggered manner to minimize interference and optimize space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If conductor ends are interlocked in opposite tangential directions with minimal axial offset, then winding head height is reduced, but installation space and active lamination length remain insufficiently optimized
Solution Approach 1:
The patent transitions from conventional tangential interlocking to radial interlocking of conductor ends. The conductor ends are guided into radial slots and interlocked in the radial direction, creating a multi-dimensional arrangement that reduces axial winding head height while optimizing the power-to-length ratio through improved spatial utilization.
Solution Approach 2:
The conductor ends are nested within radial slots of the base body, with multiple conductor ends arranged concentrically within the same radial slot. This nesting arrangement allows compact packing of conductor ends in the radial direction, minimizing axial protrusion and reducing winding head height.
2Quantity of substance
If multiple conductor loops are inserted into the same slot to increase turns, then winding density increases, but conductor end interference and winding head height increase
Solution Approach 1:
Instead of increasing turns by adding more conductor loops in the axial direction (which increases winding head height), the patent arranges multiple conductor ends within radial slots, utilizing the radial dimension for compact turn arrangement. This maintains low winding head height while achieving high turn density.
Solution Approach 2:
Different regions of the conductor arrangement are optimized for different functions: the radial slots provide localized compact packing for multiple turns, while the axial region maintains minimal protrusion for low winding head height. This local optimization allows high turn density without increasing overall winding head height.
Data Source
Figure 1(a)
Figure 1(b)
Figure 2(a)
AI summary
The present invention relates to a stator or rotor for an electrical machine, comprising - a main body which extends concentrically about an axis from a first end, in the axial direction, to a second end and in which slots are arranged in a manner distributed uniformly in a tangential direction in relation to the axis, and comprising - conductor loops which are inserted into the slots and which each have a first conductor end and a second conductor end, which conductor ends each protrude out of the main body at one end of said main body, wherein in each case the first conductor ends of a conductor loop are interleaved in relation to the second conductor ends of the same conductor loop in opposite tangential directions in relation to the axis, wherein in each case the first conductor end of one of the conductor loops is electrically conductively connected to a second conductor end of another conductor loop, which is offset from it by a number of slots, at a connecting point, wherein in each case the first conductor end is additionally interleaved into a inner winding space part which is arranged in front of the slots in the radial direction in relation to the axis and/or in each case the second conductor end is interleaved into an outer winding space part which is arranged behind the slots in the radial direction in relation to the axis. The present invention additionally relates to an electrical machine comprising a stator or rotor of this kind, to an adjusting drive for a motor vehicle comprising an electrical machine of this kind, and also to a method for producing the stator or rotor.