Stator With Radially-Nested U-Shaped Conductors
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Solution Overview
Problem
Conventional electric machine stators have significant electrical losses, weight, and volume due to the length and electrical resistance of end-turns, which cross axially over each other, and existing additive manufacturing methods have not enabled the manufacture of distributed windings without these cross-overs.
Innovation Solution
A stator design featuring radially-nested U-shaped conductors and bridges with non-conductive casings, allowing end-turns to be arranged in a radially-nested relationship without crossing, and utilizing additive manufacturing for reduced material usage and electrical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional hairpin conductors are used with axial cross-overs, then the winding can be manufactured using traditional methods, but the end-turn length and electrical resistance increase significantly
Solution Approach 1:
The patent transitions from conventional axial end-turn cross-overs to a radial arrangement where end-turns are positioned in different radial planes. This dimensional change eliminates the need for axial cross-overs, reducing end-turn length and electrical resistance while maintaining manufacturability through modular assembly of conductor segments.
Solution Approach 2:
The patent divides the winding into multiple separately manufactured sub-assemblies (conductor segments) that are subsequently assembled. This segmentation allows each segment to be optimized independently and facilitates the radial arrangement of end-turns, reducing overall winding length and electrical resistance.
2Loss of energy
If end-turns are reduced in length, then electrical losses and weight are reduced, but the complexity of winding assembly increases
Solution Approach 1:
The winding is divided into multiple conductor segments that can be manufactured separately using conventional or additive manufacturing methods. These segments are then assembled in a modular fashion to achieve the reduced-length radial end-turn configuration, balancing manufacturing simplicity with performance optimization.
Solution Approach 2:
The patent introduces intermediate connection structures (such as connection pieces or transition regions) that facilitate the assembly of conductor segments. These intermediaries simplify the overall assembly process while enabling the compact radial arrangement that reduces end-turn length and electrical losses.
3Quantity of substance
If additive manufacturing is used for windings, then material usage and electrical resistance are reduced, but the ability to manufacture distributed windings without axial cross-overs has not been achieved
Solution Approach 1:
The patent divides the winding into multiple sub-assemblies that can be manufactured separately using additive manufacturing. This segmentation enables the production of complex radial end-turn geometries that would be difficult to achieve in a single piece, while reducing material usage and electrical resistance through optimized conductor paths.
Solution Approach 2:
The patent employs additive manufacturing to create three-dimensional radial end-turn structures that extend in the radial direction rather than requiring axial cross-overs. This dimensional approach allows for compact winding arrangements with reduced material usage while maintaining manufacturing feasibility through layer-by-layer construction.
Data Source
AI summary
A stator for an electric machine is fabricated by assembling a core and first and second winding assemblies. The first winding assembly (FWA) is fabricated by a 3D printing process and includes a plurality of U-shaped conductors (hairpins) having respective end-turns arranged in mutually axially-nested relationship to each other to form a ring, and further having two uprights disposed in one of the slots of the core. End-turns connect respective pairs of the uprights and are disposed adjacent to an end surface of the core, distal ends of the uprights projecting axially beyond an opposite end surface of the core. The second winding assembly (SWA) includes a plurality of bridges forming a second ring Opposite ends of each bridge define terminals that mate with ends of the uprights. The SWA further includes an electrically non-conductive casing in which at least one of the bridges is embedded.