Stator Winding Terminal Layout for Heat and Vibration Control
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Solution Overview
Problem
Existing electrical connection methods for stator windings in electric machines, particularly those using multi-strand conductors like Litz wires, face challenges in retaining connections in high vibrational and high-temperature environments, and suffer from heat buildup and complex cooling issues in larger machines, especially in outer rotor designs.
Innovation Solution
The solution involves providing terminal connectors on both sides of the stator assembly for connecting windings to the power supply, allowing connections to be segregated between the front and back sides, reducing heat concentration and improving retention and cooling, while enabling maintenance access to specific failing components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bus bars are used to connect windings to power supply terminals, then electrical connection reliability is improved, but heat buildup increases and cooling becomes difficult
Solution Approach 1:
The patent divides the single-point connection system into multiple connection points distributed around the stator periphery. Instead of concentrating all electrical connections at one location using bus bars, the windings are connected to power supply terminals at multiple distributed locations, segmenting the heat generation and improving thermal management while maintaining connection reliability.
2Device complexity
If multiple bus bars are stacked at one end of the stator, then electrical connections are consolidated, but assembly and cooling complexity increases
Solution Approach 1:
The patent transitions from a one-dimensional stacked arrangement of bus bars at one end to a two-dimensional distributed arrangement of connection points around the stator periphery. This dimensional change spreads connections across multiple locations, eliminating the need for complex stacking and cooling arrangements while maintaining consolidation benefits.
3Device complexity
If conventional inner rotor design is used, then structural simplicity is maintained, but power density decreases
Solution Approach 1:
The patent incorporates the improved distributed connection system into the outer rotor design beforehand, enabling the structure to achieve higher power density from the outset. By pre-configuring the windings and connection points optimally, the outer rotor design realizes its full potential for increased power density without compromising structural simplicity.
Data Source
AI summary
A stator assembly comprising: an annular stator body around an axis, the stator body having a first side and a second side spaced axially from the first side and a stator body surface defined by the first and second sides and extending circumferentially around the axis; a plurality of conductive windings provided on the stator body surface, each conductive winding extending between the first side and the second side, the conductive windings arranged adjacent each other in the circumferential direction; and a first set of terminal connectors provided at the first side, and a second set of terminal connectors provided at the second side for conductively connecting the windings to a power supply, in use.