Stator Winding δ-Shaped Coil Pattern Reduces Coil End Diameter
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Solution Overview
Problem
Conventional rotary electric machines face challenges in minimizing the diameter of coil ends due to interphase insulation, leading to increased conductor cross-sectional area reduction and torque pulsation issues in distributed winding stators.
Innovation Solution
A stator winding configuration using jointless continuous conductor wires wound in a δ-shaped coil pattern at a pitch of one slot, with alternating axial directions in a radial direction, reduces bending radius and simplifies interphase insulation, thereby suppressing coil end diameter increases and torque pulsation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hexagonal coils are lane-changed at vertex portions to be offset by entire width, then interphase insulation is ensured, but bending radius increases and coil end diameter increases
Solution Approach 1:
The patent applies dimensionality change by transitioning from conventional planar winding to three-dimensional spatial winding. The conductor wire is wound to pass through slots at different axial positions and radial depths, creating a spatial configuration where coil ends overlap in the axial direction rather than extending radially. This reduces coil end diameter while maintaining interphase insulation through the insulating coating on the jointless continuous conductor wire.
Solution Approach 2:
The patent employs dynamics by using a flexible jointless continuous conductor wire that can be wound into complex three-dimensional paths. The conductor wire dynamically adapts to the winding pattern, passing through multiple slots at different positions and creating a compact spatial arrangement that reduces coil end dimensions while ensuring insulation between phases.
2Length of stationary object
If wave windings are disposed in multiple layers radially, then bending radius is reduced, but interphase insulation requirements increase coil end diameter
Solution Approach 1:
The patent merges multiple winding functions into a single jointless continuous conductor wire that performs both the winding function and the insulation function. The insulating coating is applied to the conductor wire itself, eliminating the need for separate insulating layers between radial layers. This integration reduces coil end diameter while maintaining reliable interphase insulation.
Solution Approach 2:
The conductor wire serves itself by having the insulating coating applied directly to it, making the conductor wire self-insulating. This self-service approach eliminates the need for additional insulating materials and complex insulation structures, reducing coil end diameter while ensuring interphase insulation between radially disposed wave windings.
3Reliability
If thick insulating coating or insulating papers are used, then interphase insulation is ensured, but conductor cross-sectional area is reduced
Solution Approach 1:
The patent uses a thin insulating coating film applied to the conductor wire instead of thick insulating materials. This thin film provides sufficient interphase insulation while minimizing the reduction of conductor cross-sectional area. The flexible thin film coating allows the conductor wire to be wound into compact three-dimensional configurations without requiring additional insulation space.
Data Source
AI summary
A stator winding includes forty-eight winding bodies 22 that are each produced by winding a jointless continuous conductor wire that is coated with insulation, and that are arranged at a pitch of one slot in a circumferential direction so as to be mounted into a first slot 131, a second slot 132, and a third slot 133 that are circumferentially consecutive at an angular spacing of six slots. The winding bodies 22 are configured into a δ-shaped coil pattern that is formed by inserting the conductor wire 19 sequentially into the first slot 131, the second slot 132, the third slot 133, and the second slot 132, so as to alternate an axial direction of insertion into the first slot 131, the second slot 132, and the third slot 133.