Stator Winding With Alternating End Turn Pitches
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Solution Overview
Problem
Existing electric machine designs face challenges in achieving reduced electrical resistance, smaller size, and easier manufacturing while meeting predetermined performance characteristics, particularly in winding arrangements.
Innovation Solution
The stator core with a winding arrangement featuring multiple winding paths with alternating pitches, where the end turns of one path nest with those of another, allowing for a compact and efficient configuration that simplifies manufacturing by using identical wire shapes rotated to create different paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional winding arrangements are used, then manufacturing is simpler, but electrical resistance is higher and size is larger
Solution Approach 1:
The winding is divided into multiple discrete parallel paths with alternating pitches, where each path consists of slot segments and end turns. This segmentation allows for optimized current distribution and reduced electrical resistance while maintaining manageable manufacturing complexity through standardized path configurations.
Solution Approach 2:
End turns of different parallel paths are nested together in a compact arrangement, with inner layer end turns positioned within outer layer end turns. This nesting reduces the overall machine size and improves space utilization while maintaining the complex multi-path winding structure.
2Reliability
If winding paths with alternating pitches are used, then electrical resistance is reduced, but manufacturing complexity increases
Solution Approach 1:
Multiple parallel paths share common structural elements including identical slot segment designs and standardized end turn configurations. The alternating pitch pattern is achieved through systematic variation of a base design, allowing for reduced electrical resistance while simplifying manufacturing through component standardization and repeatability.
Solution Approach 2:
The winding pitch parameter alternates between different values for adjacent parallel paths, creating an optimized current distribution pattern that reduces electrical resistance. This parameter variation is implemented systematically across the winding structure while maintaining overall manufacturing simplicity through consistent construction methods.
3Volume of moving object
If compact nested end turns are used, then machine size is reduced, but winding path complexity increases
Solution Approach 1:
End turns are arranged in nested layers where inner layer end turns are positioned within outer layer end turns, creating a compact configuration that reduces machine size. This nesting systematically organizes the complex multi-path winding structure into a space-efficient arrangement.
Solution Approach 2:
The nested end turn arrangement utilizes the axial dimension of the machine to organize winding paths in layers, transitioning from a two-dimensional planar arrangement to a three-dimensional nested structure. This dimensional change enables compact size reduction while systematically managing winding path complexity.
Data Source
AI summary
A stator for an electric machine includes a stator core with a multi-phase winding arranged on the stator core. The stator core has a plurality of slots formed therein and defines a first axial end and a second axial end. The multi-phase winding includes multiple parallel paths for each winding phase, each parallel path completing multiple revolutions around the stator core, and each parallel path comprising a series of slot segments arranged in layers of the plurality of slots and end turns alternately connecting consecutive slot segments on the first axial end and the second axial end. A pitch of the end turns connecting the slot segments for at least one parallel path alternates between a first pitch on the first axial end and a second pitch on the second axial end, the second pitch being different from the first pitch.