Stator Interconnection Web Layout for Compact Bar Conductor Joining
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Solution Overview
Problem
Existing stator designs face challenges in simplifying the connection of bar conductors for composite windings, requiring complex assembly and large installation space, while also seeking a secure and cost-effective electrical connection.
Innovation Solution
The stator features radially distributed bar conductors with arcuate interconnection webs forming groups, allowing for compact electrical connections and reduced installation space, utilizing prestressable contact surfaces for secure bonding through welding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate copper connectors or interconnection bridges are used to connect segment conductors, then electrical connection is achieved, but assembly complexity increases and installation space increases
Solution Approach 1:
The interconnection bridge is integrated directly into the stator core structure, merging the function of electrical connection with the structural support function. This eliminates the need for separate connection components and reduces assembly complexity while maintaining reliable electrical connection between segment conductors.
Solution Approach 2:
The stator core structure serves multiple functions: it provides mechanical support for the segment conductors and simultaneously provides the interconnection bridge for electrical connection. This multi-functional design reduces the number of separate components needed and simplifies the overall assembly process.
2Device complexity
If segment conductors are connected directly without interconnection bridges, then assembly is simplified, but the resulting winding head has considerable height
Solution Approach 1:
The interconnection bridge is arranged in the radial direction of the stator core, utilizing the radial dimension rather than extending the winding head height in the axial direction. This dimensional reorientation allows for direct connection of segment conductors while maintaining compact overall dimensions.
Solution Approach 2:
The interconnection bridge is nested within the stator core structure, with the bridge forming part of the core's internal geometry. This nesting allows the connection structure to be contained within the existing radial space of the stator, avoiding additional height requirements.
3Area of stationary object
If interconnection webs are arranged in groups along different interconnection levels, then radial installation space is optimized, but the number of interconnection levels increases
Solution Approach 1:
The interconnection webs are divided into groups, with each group assigned to specific bar conductor groups at different interconnection levels. This segmentation allows for systematic organization of connections while maintaining clear spatial relationships and facilitating manufacturing processes.
Solution Approach 2:
Different interconnection web groups are positioned at specific radial locations and interconnection levels according to the local requirements of different bar conductor groups. This localized arrangement optimizes the use of radial installation space while maintaining necessary electrical connections throughout the stator structure.
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 configuration simplifies the assembly of composite windings, reduces installation space, and optimizes electrical connections, minimizing line losses and material usage while maintaining efficiency.
Implementation Method 1
optimizes electrical connections, minimizing line losses and material usage while maintaining efficiency
Data Source
Figure 1~2
Figure 3~4
Figure 5a~5e
AI summary
The invention relates to a stator (1) for an electric machine, comprising a plurality of rod conductors (10) and a plurality of interconnection pieces (20). The interconnection pieces (20) each have a curved shape, in particular the shape of a C, extending in the radial direction and about the axis of rotation (X) of the stator (1); in order to form respective interconnection planes (6) along the axis of rotation (X), each group (5) of interconnection pieces is arranged in the region of at least one short end of the rod conductors (10) of the associated group (4) of rod conductors that are to be electrically connected. The invention further relates to a connection component and an electric machine.