Motor Stator Wave Winding Layout for Lower Harmonics
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Solution Overview
Problem
Existing motor winding methods, such as U-shaped and I-shaped windings, require multiple welds, limiting reliability and design flexibility, while wave windings can cause uneven phase winding and increased harmonic components leading to noise and torque fluctuations.
Innovation Solution
A motor stator winding design with continuously wound undulating wires using normal, jumper, and dislocation pitches, reducing welds and harmonics by alternating wire sequences in the circumferential direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If U-shaped or I-shaped winding methods are used, then the winding process can be automated, but the number of welding spots increases, reducing reliability
Solution Approach 1:
The patent changes the winding parameters by using continuous wave winding with specific pitch variations (normal pitch, jumper pitch, dislocation pitch) instead of traditional U-shaped or I-shaped winding parameters, thereby reducing welding spots while maintaining automation capability
Solution Approach 2:
The patent segments the continuous winding into different pitch sections (normal, jumper, dislocation pitches) to achieve both automation compatibility and reduced welding requirements through strategic placement of wire groups
2Reliability
If wave winding is used, then the number of welding spots is reduced, but improper pitch may cause uneven phase winding distribution and increased harmonic components
Solution Approach 1:
The patent applies periodic action by systematically alternating between normal pitch, jumper pitch, and dislocation pitch in a repeating pattern, which evenly distributes phase windings and reduces harmonic components through regular rhythmic variation
Solution Approach 2:
The patent uses asymmetric pitch variations (jumper pitch and dislocation pitch differ from normal pitch) to create intentional asymmetry in the winding pattern, which balances the overall phase distribution and reduces harmonic distortion
3Ease of manufacture
If continuous wave winding is used, then production is more convenient, but harmonic components increase causing noise and torque fluctuation
Solution Approach 1:
The patent implements periodic pitch variation (normal, jumper, dislocation) in the continuous wave winding process, which maintains manufacturing convenience while systematically reducing harmonic components that cause noise and torque fluctuation
Data Source
AI summary
A motor stator having stator windings as polyphase windings wound onto a stator core. The winding is continuously wound in a wave shape with 2N winding layers, S winding phases, and 2P poles of each phase winding. 4×S×P slots are formed in the core. Each pole of each phase has two conducting wire groups, each group has two conducting wires wound in parallel in adjacent slots, and the pitch of each conducting wire group is a normal pitch of y, a jumper pitch of y+1, and a dislocation pitch. The jumper pitch has a first pitch of y−1 and a second pitch of y+1. The dislocation pitch has a third pitch of y and a fourth pitch of y+2. One jumper pitch is used for each conducting wire group at every P−1 non-jumper pitch. One dislocation pitch is used for each conducting wire group between at least two adjacent layers.