Stator Winding Axial Length Reduction via Coil Rotation
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Solution Overview
Problem
Existing methods for producing stator windings in electrical machines result in axial overhangs that are not optimally shortened, leading to inefficiencies in space utilization and cooling, and require complex handling and sorting of coil sides during production.
Innovation Solution
A method for producing a stator winding with a continuous wire that allows for a short axial length by rotating coils 90° relative to each other, enabling independent embossing of coil sides and flexible slot fill factors, which improves cooling and space utilization, and simplifies the production process by allowing for easier insertion and alignment of phase windings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional stator winding production methods are used, then the stator winding can be produced, but the axial overhang of coil side connectors is not optimally shortened, leading to increased axial length
Solution Approach 1:
The stator winding is segmented into multiple phase windings, each consisting of discrete coils that can be independently produced and then assembled. This segmentation allows for simplified handling during manufacturing while achieving the desired compact axial length through systematic arrangement of the segmented components.
Solution Approach 2:
The patent employs a multi-layer arrangement of coils in the axial dimension, with coils positioned at different axial levels and connected through coil side connectors. This dimensional approach allows the winding to achieve compact axial length while maintaining ease of manufacture through modular assembly of coils from different layers.
2Ease of manufacture
If coil sides are embossed together as a group, then the embossing process is simpler, but the coil sides near the yoke and on the slot side cannot be embossed independently
Solution Approach 1:
The embossing process is segmented into separate operations for different coil side groups. Coil sides near the yoke can be embossed independently from those on the slot side, allowing each group to be optimized for its specific function while maintaining overall manufacturing efficiency.
Solution Approach 2:
Certain coil sides are embossed in advance during coil production, while other embossing operations are performed later during assembly. This preliminary action allows yoke-side coil sides to be prepared beforehand, enabling independent treatment and optimization of different coil side regions.
3Length of moving object
If the axial length of the stator winding is reduced, then space utilization improves, but the groove cross section becomes more constrained
Solution Approach 1:
The patent compensates for reduced axial length by utilizing the radial and circumferential dimensions more effectively. Multiple coils are arranged in different radial layers and angular positions, allowing the groove cross section to be optimized for electrical performance while maintaining compact axial length through three-dimensional space utilization.
Solution Approach 2:
Coils are nested in multiple radial layers within the stator winding structure, with inner-layer coils positioned radially inside outer-layer coils. This nesting arrangement allows the winding to achieve compact axial length while providing flexibility in groove cross section design through the layered configuration.
Data Source
Figure 1
Figure 2~3
Figure 4a~4b
AI summary
The invention relates to a method for producing a stator winding (18) of an electric machine (10), in particular of an alternator, the stator winding (18) comprising at least n phase windings (120, 121, 122, 123, 124) and a phase winding (120, 121, 122, 123, 124) having several directly consecutively wound coils (82) having coil sides (88) and coil side connectors (91), the coils (82) being divided into first coils (82.1) and second coils (82.2), by means of a forming tool (100), in which grooves (105, 106; 105', 106') suitable for accommodating the coils (82) are provided, a first coil (82.1) being arranged in one groove (105; 105') and a second coil (82.2) being arranged in another groove (105; 105'), characterized in that n-1 grooves (105, 106; 105', 106') are arranged between the first coil (82.1) and the second coil (82.2).