Stator Winding Layout to Shorten Rotary Electric Machine Axial Length
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Solution Overview
Problem
Existing rotary electric machines face issues of increased axial length and poor manufacturability due to the connection of identical-phase coil portions at opposite ends and the need for crossover wires, which complicates winding operations.
Innovation Solution
The rotary electric machine design leads out lead wires of identical-phase winding portions in a first axial direction and crossover wires in a second axial direction, reducing the number of crossover wire intersections and utilizing vacant spaces to shorten the stator axial length, thereby improving manufacturability and workability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If identical-phase coil portions are connected at opposite ends from electric power supplying portions, then the number of connections is reduced, but the axial length of the stator is increased and winding operations become difficult
Solution Approach 1:
The patent changes the spatial arrangement of connections by leading out lead wires in the axial direction rather than connecting at opposite ends, transforming a one-dimensional connection pattern into a three-dimensional arrangement that reduces axial length while maintaining connection efficiency
Solution Approach 2:
Instead of connecting identical-phase coil portions at opposite ends from electric power supplying portions, the patent inverts the connection approach by leading out lead wires from adjacent identical-phase coil portions in the axial direction, thereby reducing the axial length requirement
2Device complexity
If crossover wires are used to connect identical-phase coil portions in parallel circuits, then the number of parts is reduced, but the axial length of the stator is further increased
Solution Approach 1:
The patent merges the functions of lead wires and crossover wires by having lead wires perform both the function of connecting identical-phase coil portions and serving as crossover wires for parallel circuit connections, thereby eliminating the need for separate crossover wires and reducing axial length
Solution Approach 2:
The lead wires are designed to serve multiple functions: connecting identical-phase coil portions in series and simultaneously acting as crossover wires for parallel circuit connections, thereby reducing the number of separate components needed and shortening the axial length
3Length of stationary object
If different-phase crossover wires are disposed inside a single slot, then the axial length of the stator is shortened, but the workability of the windings is poor
Solution Approach 1:
The patent applies different spatial arrangements to different types of wires: lead wires are led out in the axial direction from adjacent identical-phase coil portions, while crossover wires are led out in the circumferential direction, creating localized optimization that improves both axial length and winding workability
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 facilitates winding connections, reduces the size of the rotary electric machine, and enhances workability by shortening the stator axial length while improving space factor and torque.
Implementation Method 1
an armature winding 4 that has, among coil portions in which conducting wires are wound onto stator core teeth
Data Source
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AI summary
A rotary electric machine includes: a rotor that includes a plurality of magnetic poles; and a stator that is disposed so as to surround the rotor, the stator including: a stator core that includes teeth that extend from a core back in a radially inward direction of the rotor; and an armature winding that is mounted to the stator core. The armature winding is constituted by a plurality of identical-phase winding portions in which identical-phase coil portions among coil portions in which conducting wires are wound in concentration onto respective teeth are connected together into a series circuit by means of crossover wires, and that also have lead wires at two end portions. Each of the lead wires of each of the identical-phase winding portions is led out in a first axial direction of the rotor from coil portions that have identical phase, that are disposed so as to be adjacent in a circumferential direction of the stator core; and all of the crossover wires of each of the identical-phase winding portions are led out in a second axial direction of the rotor.