Stator Winding Crossover Layout for Compact Rotary Electric Machines
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Solution Overview
Problem
Existing rotary electric machines face challenges in achieving compact size and ease of manufacturing due to the arrangement of crossover wires of the stator coil along the insulator, which complicates the structure and increases the axial length.
Innovation Solution
A rotary electric machine design featuring a multi-phase winding with magnetic poles arranged circumferentially, utilizing inter-pole and end crossover wires that connect same-phase single coils, where the inter-pole crossover wires extend through inter-pole gaps between adjacent magnetic poles, reducing the length of end crossover wires and minimizing the number of phase connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If crossover wires are arranged along the insulator of the stator, then the stator coil structure is formed, but the axial length increases and manufacturing becomes complicated
Solution Approach 1:
The patent transitions the crossover wire arrangement from a conventional axial stacking configuration to a radial configuration where wires extend through inter-pole gaps between adjacent magnetic poles. This dimensional change allows the wires to utilize the radial space between poles rather than stacking axially, thereby reducing the axial length while maintaining electrical connectivity between coils.
Solution Approach 2:
The patent divides the crossover wire into two distinct segments: an inter-pole crossover wire portion that extends through the inter-pole gap between adjacent magnetic poles, and an end crossover wire portion that extends in the circumferential direction. This segmentation allows each portion to be optimized for its specific function and simplifies the overall manufacturing process by clearly defining wire routing paths.
2Reliability
If more crossover wires are used to connect same-phase coils, then electrical connectivity is improved, but device complexity increases
Solution Approach 1:
The patent merges the functions of multiple crossover wires by having a single crossover wire serve dual purposes: connecting coils of the same phase through the inter-pole gap and providing electrical pathways for multiple phases. This consolidation reduces the total number of crossover wires needed while maintaining reliable electrical connectivity across all phases.
Solution Approach 2:
The inter-pole crossover wire is designed to perform multiple functions simultaneously: it connects same-phase coils, provides electrical pathways for different phases, and maintains structural integrity across the air gap. This multi-functionality reduces the overall complexity of the winding structure while ensuring reliable electrical connections.
Data Source
AI summary
A rotary electric machine includes a multi-phase winding including magnetic poles circumferentially arranged in a circumferential direction. The multi-phase winding includes crossover wires. Each crossover wire connects two single coils functioning as two of the magnetic poles that are same in phase. The crossover wire includes an inter-pole crossover wire and an end crossover wire. The inter-pole crossover wire extends between one end and another end of the multi-phase winding in an axial direction of the multi-phase winding. The inter-pole crossover wire extends through an inter-pole gap between adjacent two of the magnetic poles. The end crossover wire extends in the circumferential direction on the other end of the multi-phase winding.