Stator Segment Coil Resistance Measurement via Exposed Conductors
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Solution Overview
Problem
Existing stators for rotating electrical machines face challenges in identifying connection failures between segment coils, leading to potential power loss and reduced reliability due to the inability to accurately measure electric resistance at specific connection points.
Innovation Solution
A stator design with segment coils connected via coupling members, where conductor-exposed portions are strategically positioned near connection points to allow for accurate resistance measurement using probes, enhancing the identification and rectification of connection failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the electric resistance of the entire stator coil is measured by causing a current to flow through the stator coil, then the measurement process is simple, but the connection portion where connection failure occurs cannot be identified
Solution Approach 1:
The stator coil is divided into multiple segment coils, each with identifiable conductor-exposed portions. This segmentation allows resistance measurement to be performed at specific connection portions between segment coils rather than measuring the entire coil as a single unit, enabling identification of which specific connection has failed.
Solution Approach 2:
Conductor-exposed portions are introduced as intermediary elements between the segment coils and the measurement probes. These exposed conductor portions facilitate direct contact with probes at specific connection locations, serving as mediators that enable precise localization of connection failures while maintaining measurement simplicity.
2Ease of manufacture
If segment coils are connected together to form the stator coil, then the manufacturing flexibility is improved, but the reliability decreases due to inability to identify connection failures
Solution Approach 1:
The conductor-exposed portions provide a feedback mechanism by enabling resistance measurement at each connection portion. This feedback allows detection of connection failures in specific segment coil connections, providing information about the reliability status of each connection point while maintaining the manufacturing flexibility of using multiple segment coils.
Solution Approach 2:
Conductor-exposed portions are prepared in advance during the manufacturing process, positioned at predetermined locations where connections will be made. This preliminary preparation enables subsequent resistance measurements to be performed efficiently without requiring additional manufacturing steps, thus maintaining manufacturing flexibility while improving reliability monitoring capability.
3Measurement precision
If conductor-exposed portions are added to segment coils for resistance measurement, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
Conductor-exposed portions are added only at specific local positions where connections between segment coils occur, rather than exposing conductors throughout the entire coil structure. This localized approach provides the necessary measurement precision at critical connection points while minimizing the increase in overall device complexity.
Data Source
AI summary
A coil includes a plurality of segment coils. Ends of two corresponding segment coils are electrically connected together via a coupling member or by being fitted together. Each of the plurality of segment coils includes a conductor-exposed portion located close to a connection portion between the corresponding segment coils and to be brought into contact with a probe of a resistance measurement apparatus. When the coil is manufactured, the ends of the plurality of segment coils are electrically connected to the ends of other corresponding segment coils, and electric resistances of connection portions between the ends are measured for each layer of the ends of the segment coils.