Stator Segmented Winding Coil End Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rotary machine stators face challenges in easily changing terminal voltage and have difficulty in making coil ends smaller, especially when using unit coils composed of identical coil wire elements.
Innovation Solution
A stator design featuring a stator core with segments formed into hairpin shapes from rectangular wires, where different segments have varying slot pitches, allowing for alternate and concentric arrangement of unit coils, enabling connection to tip ends or neutral points, and allowing for series or parallel wiring configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If unit coils are composed of identical coil wire elements arranged in the same manner, then the manufacturing process is simplified and standardized, but the coil end size cannot be reduced and the design lacks adaptability to different voltage specifications
Solution Approach 1:
The stator winding is segmented into multiple unit coils, each comprising a specific number of slots (e.g., 2 slots per pole per phase). These unit coils can be independently configured with different slot pitches while maintaining standardized coil wire elements, enabling both manufacturing simplicity and design flexibility for different voltage requirements
Solution Approach 2:
Different unit coils are assigned different slot pitches locally (e.g., first unit coil with slot pitch of 6, second unit coil with slot pitch of 7), allowing optimization of coil end size and voltage characteristics in specific regions while maintaining standardized coil wire elements throughout the stator
2Ease of manufacture
If traditional winding arrangements are used with identical unit coils, then the manufacturing process is straightforward, but the coil end size cannot be reduced
Solution Approach 1:
Unit coils are configured with different slot pitches (asymmetric arrangement), where the first unit coil has a different slot pitch than the second unit coil. This asymmetric configuration optimizes the coil end geometry to reduce coil end size while maintaining a straightforward manufacturing process using standardized coil wire elements
3Adaptability or versatility
If the terminal voltage needs to be changed, then the electrical characteristics can be adjusted, but the winding wire arrangement must be reconsidered and redone
Solution Approach 1:
The stator is designed with multiple unit coils that can be connected in different configurations (series, parallel, or combinations) to achieve different terminal voltages. The standardized coil wire elements and modular unit coil structure allow the same physical arrangement to serve multiple voltage specifications through different connection methods, eliminating the need to redesign the winding wire arrangement for voltage changes
Data Source
Figure 1
Figure 2
Figure 3
AI summary
In order to provide a rotary machine's stator that is capable of reducing the size of the coil ends and using a plurality of voltages without changing the winding arrangement, it is made to include a stator core (12) having a plurality of slots (14) provided along the circumferential direction, segments (22) that are composed of rectangular wires and received in the slots (14), and a distributed winding wire that is formed by arranging unit coils (21), each of which is made up of a plurality of the segments (22) disposed along the radial direction, in the circumferential direction of the stator core (12), and is made to form the unit coil (21) by connecting the segments (22) that are alternately and concentrically arranged in the radial direction with a plurality of slot pitches that are different from each other.