Electric Machine Stator Winding End Loop Arrangement
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Solution Overview
Problem
Conventional electric machine winding arrangements face spatial conflicts at the axial ends of the stator due to the placement of reversing loops and neutral connections, which can lead to reduced output and magnetic noise, especially in designs with large hairpins and internal fans.
Innovation Solution
The proposed solution involves a stator winding arrangement where at least 60% of the end loops connect slot segments in different layer positions, allowing for efficient use of space by positioning slot segments in multiple layers within each stator slot, with select stator slots having slot segments in different layer positions connected by end loops, and the neutral connection is formed by a conductor extending less than 360 degrees, optimizing the radial distribution of windings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional winding arrangements are used with reversing loops and neutral connections at the same axial end, then the winding structure is simple, but spatial conflicts occur at the axial ends of the stator
Solution Approach 1:
The patent applies layer positioning in the radial dimension to resolve spatial conflicts. By placing slot segments in different layer positions (first layer and second layer) and connecting them through end loops, the design utilizes the radial dimension to accommodate multiple connections without axial space conflicts. This dimensional transition from axial to radial organization allows the neutral connection and reversing loop to coexist without interfering with each other or with the internal fan.
2Quantity of substance
If large hairpins are used to form stator windings, then the conductor cross-sectional area increases, but spatial conflicts at the axial ends of the stator worsen
Solution Approach 1:
The patent resolves the spatial conflict caused by large hairpins by transitioning to a multi-layer radial arrangement. Instead of accommodating all connections in the axial dimension, the design places slot segments in different radial layers and connects them through end loops that extend in the radial direction. This allows large hairpin conductors to be positioned in multiple layers without requiring excessive axial end space.
3Device complexity
If neutral connection and reversing loop are located in the same layer, then the winding arrangement is conventional, but spatial conflicts arise requiring axial displacement
Solution Approach 1:
The patent resolves the spatial conflict between neutral connection and reversing loop by utilizing the radial layer dimension. Instead of placing both connections in the same axial position, the design positions slot segments in different layer positions (first layer and second layer) and connects them through end loops. This radial separation eliminates the need for axial displacement while maintaining a conventional-looking winding arrangement from the axial view.
4Adaptability or versatility
If multiple windings are used for multi-phase electric machines, then the machine can handle multiple phases, but spatial difficulties at the axial end multiply
Solution Approach 1:
The patent enables multi-phase capability while reducing axial end space requirements by implementing a multi-layer radial arrangement. Each phase winding utilizes the available layer positions in the radial dimension, with slot segments distributed across different layers and connected through end loops. This three-dimensional organization allows multiple windings to coexist without proportionally increasing axial end space occupancy.
Data Source
AI summary
An electric machine including a rotor and a stator and having a first winding. The stator slots define a plurality of layer positions wherein each of the layer positions is at a different radial distance from the axis. There is an odd number of select stator slots wherein for two slot segments disposed in different layer positions, a pair of end loops connect each of the slot segments with another slot segment in a different slot that is in the same layer position. In some embodiments, at least 60 percent of the end loops connect slot segments that are disposed in different layer positions. For some embodiments, only a single select stator slot is provided with the end loops being positioned to reduce spatial conflicts.