Stator Coil Segment Inclination for Axial Miniaturization
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Solution Overview
Problem
The challenge in designing a smaller rotary electric machine stator is exacerbated by the overlapping of coil segments in the radial and axial directions, which complicates the achievement of a compact design without interfering with the stator core.
Innovation Solution
The stator design incorporates a ring-shaped yoke with teeth and slots, where rectangular wires with inclined bridge parts are arranged to minimize interference, allowing for a more compact configuration by optimizing the inclination angles of bridge parts and their positioning relative to the stator core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If coil segments are arranged to be inclined with respect to the axial direction to prevent radial interference, then radial space utilization is improved, but axial length increases making miniaturization difficult
Solution Approach 1:
The patent applies dimensional transformation by arranging coil segments along the circumferential direction rather than purely axially. The bridge parts connect adjacent coil segments in the circumferential direction, allowing the coil assembly to utilize the circumferential dimension for packing density while maintaining compact axial length, thus resolving the contradiction between radial space utilization and axial length.
Solution Approach 2:
The patent divides the coil structure into multiple discrete coil segments with bridge parts connecting them. This segmentation allows independent optimization of each segment's position and angle, enabling dense packing in the radial direction while the bridge parts manage the connections in the circumferential direction, preventing axial length extension.
2Productivity
If coil segments are densely packed to achieve compact design, then productivity and miniaturization are improved, but interference between adjacent coil segments increases
Solution Approach 1:
The patent introduces bridge parts as intermediary elements between adjacent coil segments. These bridge parts serve as mediators that connect the coil segments while maintaining proper spacing and electrical connections, allowing dense packing without direct interference between the main body of adjacent coil segments, thus enabling miniaturization while preventing harmful interference.
Solution Approach 2:
The patent applies different spatial arrangements to different parts of the coil structure. The coil segments are positioned with specific inclination angles relative to the axial direction, while the bridge parts are positioned to connect them in the circumferential direction. This local differentiation of spatial quality allows dense overall packing while maintaining clear separation between adjacent coil segment bodies, preventing interference.
Data Source
AI summary
According to one embodiment, in a stator, bridge parts of seventh coil segments extend in a direction departing from one end surface while being inclined at a predetermined inclination angle from an axial direction of a stator core to the outside of a radial direction. Regarding the bridge parts of the seventh coil segments adjacent to each other in the radial direction of the stator core, when the same cross-sections defined by the radial direction and the axial direction is viewed from a circumferential direction of the stator core, a first inclination angle of the bridge part positioned relatively in an inner side of the radial direction is smaller than a second inclination angle of the bridge part positioned relatively in an outer side of the radial direction.