Three-Phase Stator Winding With Circular Bridges for Automated Assembly
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Solution Overview
Problem
Existing rotary electric machines face challenges in achieving high energy efficiency, compactness, and lightweight design while maintaining high specific performance, and their production is not easily automated.
Innovation Solution
A three-phase stator winding design with connection bridges that have a closed circular shape and are connected to coil ends using crimping forks for secure, automated assembly, supported by insulating structures, allowing for efficient current distribution and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional stator winding designs are used, then manufacturing is simpler, but energy efficiency and specific performance are lower
Solution Approach 1:
The stator winding is divided into multiple independent coils distributed in slots, with each coil having discrete ends that connect to connection bridges. This segmentation allows for optimized current distribution paths that reduce energy losses while maintaining manufacturability through modular assembly
Solution Approach 2:
The connection bridges are arranged in a three-dimensional configuration within the stator, creating multiple spatial paths for current flow. This dimensional arrangement optimizes electrical pathways to reduce resistive losses while the modular nature maintains ease of manufacture
2Power
If larger components are used to achieve high power output, then specific performance decreases, but meeting power requirements becomes easier
Solution Approach 1:
The connection bridges have varying cross-sectional areas optimized for their specific electrical load requirements. Areas with higher current density have larger cross-sections to reduce resistive losses, while areas with lower current use smaller sections, maximizing power density without increasing overall machine volume
Solution Approach 2:
The design optimizes multiple parameters simultaneously: coil winding density, connection bridge cross-sectional areas, and slot fill factors. These parameter optimizations work together to achieve high specific performance (power per unit volume) by maximizing the utilization of available space and materials
3Loss of energy
If complex winding structures are implemented to reduce power losses, then energy efficiency improves, but production automation becomes difficult
Solution Approach 1:
The winding is segmented into standardized coils with consistent end configurations that connect to modular connection bridges. This standardization enables automated assembly equipment to handle each component independently, achieving complex electrical arrangements through simple, repeatable operations
Solution Approach 2:
The connection bridges are designed with self-aligning features and standardized connection interfaces that automatically position themselves during assembly. This self-service capability reduces the need for complex automated positioning systems while maintaining precise electrical connections for optimized power loss performance
Data Source
AI summary
Three-phase stator winding of a rotary electric machine and having: a plurality of coils each of which has two opposite ends; a plurality of first connection bridges, each of which defines a star connection of three coils and constitutes a star centre of the three coils by connecting a first end of each of the three coils to one another; and three second connection bridges which define a parallel connection of the star connections, are each provided with a corresponding pin defining a terminal of the three-phase stator winding towards the outside, and each of which connects a second end of a respective coil of each star connection to one another. Each second connection bridge has a seamless circular shape closed onto itself.