Stator Segment Conductors for Rotary Electrical Machine Eddy Current Reduction
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Solution Overview
Problem
Existing stators for rotary electrical machines experience significant eddy current losses due to leakage flux, leading to heat generation and limitations in downsizing, while attempts to mitigate this with complex and costly winding conductors complicate manufacturing and increase costs.
Innovation Solution
Divide segment conductors into N-number of parallel-connected segments to increase the path resistance against leakage flux, allowing for reduced eddy current and AC copper loss without altering the conventional manufacturing process or significantly increasing costs, with optional insulating films and perpendicular stacking for further reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If segment conductors are used in conventional stator windings, then the stator structure is simple and manufacturing is easy, but eddy current loss increases significantly due to leakage flux
Solution Approach 1:
The invention divides each segment conductor into multiple sub-segment conductors (first, second, third, and fourth sub-segment conductors) along the radial direction. This segmentation increases the path resistance for eddy currents caused by leakage flux, thereby reducing eddy current loss while maintaining the overall segment conductor structure and conventional manufacturing methods
2Loss of energy
If complex winding conductors are used to reduce eddy current, then eddy current loss decreases, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The invention segments the segment conductor into multiple sub-segment conductors that are still part of the conventional segment conductor structure, rather than using entirely different complex winding conductors. This approach reduces eddy current loss through increased path resistance while avoiding the manufacturing complexity and cost increases associated with alternative solutions
Solution Approach 2:
The invention changes the internal structure parameter of the segment conductor by dividing it into multiple sub-segments, which modifies the eddy current path characteristics and reduces loss without changing the overall conductor type or requiring new manufacturing processes
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Effectively reduces eddy current and AC copper loss, enabling smaller motor designs while maintaining conventional manufacturing simplicity and avoiding cost increases, with balanced copper loss reduction across high and low-speed operations.
Implementation Method 1
eddy current is generated within the segment conductors 141 as a result of leakage flux within the slot 131 interlinking with the segment conductors 141
Implementation Method 2
resistance of the path over which eddy current flows increases in an equivalent manner, thereby reducing eddy current
Data Source
AI summary
A stator includes a ring-shaped stator core and a stator winding. The stator core has a plurality of slots arranged in a circumferential direction. The stator winding has a plurality of phase windings. Each phase winding is composed of a plurality of segment conductors 41 disposed such as to be inserted into the slots and connected in series. The segment conductor is divided into two. The phase winding is configured by two divided phase windings connected to each other in parallel. The divided phase windings are respectively configured by a plurality of segment conductors respectively connected in series such that the two divided segment conductors are in parallel with each other.