Stator Winding Connector Layout for Heat and Vibration Reliability
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Solution Overview
Problem
Existing connection methods for stator windings in electric machines, particularly in high-performance outer rotor machines, face challenges in retaining multi-strand conductors, managing heat buildup in bus bar stacks, and ensuring reliable operation in high vibrational and temperature environments.
Innovation Solution
The connection of stator windings is implemented on both sides of the stator assembly, with winding ends connected to conductive connectors such as bus bars on opposite sides, allowing for improved heat dissipation and reduced failure risk by distributing the connection load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bus bars are stacked at one end of the stator to connect windings, then electrical connection is achieved, but heat buildup becomes difficult to remove and can cause damage
Solution Approach 1:
The patent divides the connection arrangement into two separate locations (first end and second end of the stator). Windings are connected to conductive connectors at the first end, while other windings are connected at the second end. This segmentation distributes the heat-generating connections across two locations, preventing heat buildup at a single stack location and improving heat dissipation while maintaining connection reliability.
2Loss of energy
If multi-strand conductors such as Litz wires are used, then electrical losses are reduced, but it becomes difficult to retain all strands in crimp or weld connections and difficult to retain conductors in stator slots in high vibrational environments
Solution Approach 1:
The patent introduces conductive connectors as intermediary components between the multi-strand conductors and the power supply terminals. These connectors provide a reliable mechanical and electrical connection interface that can properly retain multi-strand conductors, overcoming the difficulties of direct crimping or welding while maintaining the low electrical loss benefits of multi-strand conductors.
Solution Approach 2:
The patent moves the connection interface to a different spatial location - extending connections outward from the stator ends rather than confining them within the stator body. This dimensional change allows for more robust connector designs that can properly secure multi-strand conductors against vibrational forces while maintaining electrical performance.
3Ease of manufacture
If connections are made on one side of the stator, then assembly is simplified, but heat generation in the connection stack becomes difficult to manage
Solution Approach 1:
The patent segments the connection arrangement across two ends of the stator, with different windings connected at different locations. This segmentation naturally distributes heat generation across two separate regions, improving thermal management while the modular connector design maintains assembly simplicity through standardized connection interfaces at each end.
Data Source
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AI summary
A stator assembly comprising: an annular stator body around an axis (X), the stator body having a first side and a second side spaced axially from the first side and a stator body surface defined by the first and second sides and extending circumferentially around the axis; a plurality of conductive windings provided on the stator body surface, each conductive winding extending between the first side and the second side, the conductive windings arranged adjacent each other in the circumferential direction; and a first set of terminal connectors provided at the first side, and a second set of terminal connectors provided at the second side for conductively connecting the windings to a power supply, in use.