Stator Winding Layout for Compact Brushless Motor Armatures
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Solution Overview
Problem
Existing stator configurations in brushless motors are inefficient in aggregating the end portions of the winding, leading to larger part sizes and potential vibration and noise issues.
Innovation Solution
The proposed armature configuration includes an armature core with teeth arranged circumferentially, coils formed by winding an electroconductive winding around the teeth, and electrical conductor portions routed axially along the teeth, with equal numbers of conductor portions in each coil to facilitate aggregation of the winding end portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the first and second end portions of the winding are led out from different coils, then the winding can be distributed across multiple coils, but the size of the stator parts increases and aggregation becomes difficult
Solution Approach 1:
The patent merges the first end portion and second end portion of the winding into the same coil, specifically the same slot. This consolidation allows both end portions to be aggregated at a single location, reducing the overall stator part size and simplifying the structural configuration compared to distributing them across different coils.
Solution Approach 2:
The same coil serves multiple functions by accommodating both the first end portion and second end portion of the winding. This multi-functional design enables efficient space utilization and facilitates the aggregation of winding ends without requiring additional separate structures.
2Object-affected harmful factors
If the numbers of electrical conductor portions in respective coils are unequal, then each coil can be independently optimized, but vibration and noise occur due to unbalanced magnetic forces
Solution Approach 1:
The patent applies equipotentiality by ensuring that all coils have an equal number of electrical conductor portions (equal number of effective turns). This creates a balanced magnetic field distribution around the rotor, eliminating unbalanced magnetic forces that would otherwise cause vibration and noise during motor operation.
Solution Approach 2:
The patent implements homogeneity by making the coil structures uniform across all phases, with each coil containing the same number of electrical conductor portions. This homogeneous configuration ensures consistent magnetic field generation and prevents the harmful vibrations and noises associated with asymmetric coil designs.
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 effectively aggregates the end portions of the winding, reducing the size of the stator components, minimizing vibration and noise, and simplifying assembly by ensuring equal numbers of electrical conductor portions in each coil.
Implementation Method 1
a plurality of coils formed by winding an electroconductive winding around each of the teeth
Data Source
AI summary
A stator includes a stator core having a plurality of teeth, and a plurality of coils formed respectively around the teeth. Portions of a winding, which forms the coils, constitute inter-coil connection portions that connect the coils. A first end portion and a second end portion, which are respectively one end portion and the other end portion of the winding, are led out, respectively from a second circumferential side and a first circumferential side in the coil formed around a predetermined one of the teeth, toward a first side in an axial direction. Moreover, the numbers of electrical conductor portions in the respective coils are set to be equal to each other; the electrical conductor portions are portions of the winding which form the coils and are routed in the axial direction along the teeth.