Stator Teeth Without Roots for Conductor Insertion
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Solution Overview
Problem
The existing stators in rotary electrical machines face challenges in maximizing the filling of notches with conductors, particularly in alternators designed for motor vehicle applications, where the insertion of conductors is hindered by the geometry of the teeth and notches.
Innovation Solution
A stator design with a yoke and teeth that are without tooth roots, featuring rounded corners at the input radius to facilitate conductor insertion, along with outer indexing means for precise positioning and a winding configuration where phase windings have conductors with segment structures positioned alternately in inner and outer radial layers, connecting through loop structures across notches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the stator uses conventional teeth with tooth roots, then the structural strength of the stator is maintained, but the insertion of conductors into notches is hindered and filling efficiency is reduced
Solution Approach 1:
The invention removes the tooth roots from the stator teeth, extracting the problematic geometric feature that hindered conductor insertion. By eliminating the tooth roots, the notches become more accessible and easier to fill with conductors, directly resolving the contradiction between structural strength and insertion ease.
Solution Approach 2:
The invention introduces rounded corners at the input radius of the teeth. This curvature modification facilitates the insertion of conductors by creating a more favorable geometric transition zone, allowing conductors to be pushed further into the notches without being blocked by sharp corners or tooth roots.
2Reliability
If the stator notches are fully filled with conductors, then the performance of the electrical machine is improved, but the complexity of the winding insertion process increases
Solution Approach 1:
The invention performs preliminary geometric modification of the teeth by removing tooth roots and rounding corners before conductor insertion. This preparatory action simplifies the subsequent winding insertion process by creating optimal geometric conditions, allowing full notch filling without increasing process complexity.
3Ease of manufacture
If the input radius of tooth corners is increased, then conductor insertion is facilitated, but the space available for magnetic material and windings is reduced
Solution Approach 1:
The invention applies localized geometric modification only at the input radius of the tooth corners, where it is most needed for conductor insertion. The rounding is confined to a small region (0.15-0.8mm radius) and does not extend into the main body of the teeth, thereby preserving the volume available for magnetic material and windings while still achieving the desired insertion facilitation.
Data Source
AI summary
The invention essentially relates to an outer stator (15) for a rotary electric machine, comprising a body (16) equipped with a yoke and teeth (25) arranged on the internal periphery of the yoke (26), with slots (28) being defined between pairs of teeth (25), in which the teeth do not have roots and the stator also comprises corners (31) at the free ends of the teeth (25) that are curved according to a radius (R), known as the radius of entry (R).