Stator Active Part With Segmented Coil Support
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Solution Overview
Problem
Existing stator active parts in electric motors, particularly in PM synchronous motors, face challenges with skew windings that result in partial torque participation and require costly and complex phase insulation, while unskewed multilayer windings with overlap regions are inefficient and costly to produce.
Innovation Solution
A stator active part with a yoke packet made of stamped electrical steel plates or sintered SMC material, featuring a three-strand air gap winding without overlap in the winding head region, using finely-distributed coils and coil holders with SMC inlays for improved flux guidance and reduced parasitic effects, allowing for a simpler insulation system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If skew winding is used to avoid winding head protrusion, then the stator structure is simplified, but the winding volume only partially participates in torque formation and the base field winding factor decreases to 50-60%
Solution Approach 1:
The stator active part is divided into a yoke packet and a separate coil support with coil holders. The coils are segmented and mounted on the coil support rather than being directly wound on the yoke, allowing the winding head to be positioned at the same level as the yoke without protrusion while maintaining full torque participation through proper coil distribution.
2Power
If unskewed multilayer windings with overlap regions are used to improve torque formation, then the winding volume fully participates in torque formation, but costly and complex phase insulation becomes necessary
Solution Approach 1:
The overlapping winding head regions are extracted and positioned laterally at the same level as the yoke through the coil support structure. This eliminates the need for complex phase insulation between overlapping regions while maintaining full torque participation, as the coils are distributed across multiple holders without vertical overlap.
3Object-generated harmful factors
If SMC inlays are integrated into coil holders for flux guidance, then parasitic effects like cogging torques are reduced, but the manufacturing process becomes more complex
Solution Approach 1:
SMC (soft magnetic composite) inlays are integrated into the coil holders to create a composite structure that guides magnetic flux and reduces parasitic effects like cogging torques. The SMC material combines magnetic properties with structural functionality, and the inlays can be inserted into pre-formed recesses in the coil holders, making the manufacturing process manageable despite the added complexity.
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
This design enhances torque formation efficiency, reduces production costs, and simplifies the insulation system by eliminating overlap regions and using cost-effective SMC materials for improved performance and reduced parasitic effects like cogging torques.
Implementation Method 1
coil holders with SMC inlays for improved flux guidance and reduced parasitic effects
Data Source
AI summary
The invention relates to a stator active part for an electric motor, preferably a permanent-magnet-excited synchronous machine consisting of a hollow-cylindrical yoke, comprising an inner cladding and having a receptacle space, into which a coil support is inserted, wherein the coil support consists of a peripherally-closed, hollow-cylindrical tubular body extending in the axial direction (A) of the yoke, on the outer cladding of said body a plurality of coil holders being formed, wherein a finely-distributed coil is installed on each coil holder.