Stator Winding with Distributed 3D Winding Heads
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Solution Overview
Problem
Conventional stator windings in electric alternating current machines have large winding heads that contribute significantly to weight, space requirements, and electrical losses, leading to low power density and inefficient electromagnetic behavior due to high leakage inductance and mass imbalance.
Innovation Solution
The stator winding is configured with individual coils that are connected by winding heads within a common winding layer, avoiding crossovers and using a compact, alternating pattern of conductor limbs across multiple layers to minimize axial length and space, resulting in a more compact and efficient stator design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional distributed windings with axial conductor limbs are used, then electrical induction effectiveness is improved, but winding head size and weight increase significantly
Solution Approach 1:
The patent transitions from conventional two-dimensional winding layouts to a three-dimensional configuration where winding heads are distributed across multiple axial levels. This dimensional change allows conductor limbs to be connected at different heights, reducing the planar footprint and overall size of individual winding heads while maintaining electrical connectivity and induction effectiveness.
Solution Approach 2:
The stator winding is divided into multiple discrete winding heads distributed across different axial levels rather than having large concentrated winding heads. This segmentation reduces the weight and size contribution of each individual winding head while collectively achieving the required electrical connectivity for effective induction.
2Ease of manufacture
If large winding heads are used to connect conductor limbs, then manufacturing flexibility is improved, but space requirement and axial length increase
Solution Approach 1:
The patent utilizes the axial dimension to distribute winding heads across multiple levels, transforming the problem from a two-dimensional planar constraint to a three-dimensional spatial arrangement. This allows winding heads to be positioned at different axial heights, reducing the required axial length while maintaining manufacturing flexibility for connecting conductor limbs.
3Ease of operation
If extensive winding heads with large bending radii are used, then conductor connectivity is improved, but power density decreases due to increased volume
Solution Approach 1:
The patent employs three-dimensional winding head arrangement across multiple axial levels, allowing conductors to connect at different heights with smaller bending radii. This spatial distribution reduces the volume occupied by winding heads while maintaining effective conductor connectivity, thereby increasing the overall power density of the stator.
Solution Approach 2:
The winding system is segmented into multiple smaller winding heads distributed across axial levels rather than using a few large winding heads. This segmentation reduces the volume and bending radius requirements of individual winding heads while collectively achieving the necessary conductor connectivity for effective operation.
4Ease of operation
If winding heads bridge large circumferential regions, then phase connectivity is improved, but leakage inductance and mass imbalance increase
Solution Approach 1:
The patent segments the winding connection function into multiple distributed winding heads across different axial levels rather than using large winding heads that bridge extensive circumferential regions. This segmentation reduces the circumferential span of each winding head, thereby reducing leakage inductance and improving electromagnetic behavior while maintaining phase connectivity.
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 achieves a higher power density by reducing the size and weight of winding heads, minimizing conductor material not used for induction, and optimizing electromagnetic behavior, leading to improved mass and power loss balances.
Implementation Method 1
a plurality i of axially oriented conductor limbs that make up a substantial part, which is effective for electrical induction, of the winding
Data Source
AI summary
A stator for an electric alternating current machine includes a stator winding arranged about a central axis and including conductor windings. The conductor windings are grouped to form electrical phases. The stator winding has winding layers. The conductor windings of a phase each have axially oriented conductor limbs that are connected to one another in two axial end regions in pairs by two winding heads. Individual coils are thus formed for each phase. As viewed in a circumferential direction, the axial conductor limbs of the individual phases follow one another in alternation in a uniform order. The winding heads of a given individual coil extend within a winding layer. A sequence of the axial conductor limbs of the respective phases and the distribution of the individual coils on the individual winding layers are chosen to avoid crossovers within the individual winding layers in the region of the winding heads.