Automated Two-Layer Stator Winding with Equipotential Insulation
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Solution Overview
Problem
The existing methods for winding two-layer windings on hollow cylindrical stators for three-phase synchronous or asynchronous machines require manual intervention, leading to increased manufacturing costs and effort, as well as electromagnetic asymmetry due to the need for interlayer insulation.
Innovation Solution
A method for automatically winding two-layer windings onto a hollow cylindrical stator, where individual coils are inserted in pairs as base and top layer windings without intermediate insulation, minimizing electromagnetic stress and eliminating the need for manual intervention by using a winding machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual intervention is used to arrange coils in two-layer windings, then correct arrangement is achieved, but manufacturing costs and effort increase
Solution Approach 1:
The coils are pre-assembled into complete phases on a template before being drawn into the stator slots. This preliminary arrangement ensures correct positioning is established once, during the template winding stage, rather than requiring repeated manual adjustments during final assembly. The template acts as a guide that maintains the precise geometric structure of the winding throughout the drawing-in process.
2Reliability
If interlayer insulation is used between base and top layer windings, then electrical insulation is provided, but electromagnetic asymmetry increases
Solution Approach 1:
The patent applies equipotential insulation, where the insulation layer is electrically connected to both the base winding and top layer winding at their respective ends. This creates an equipotential surface that eliminates potential differences between layers, preventing electromagnetic asymmetry while still providing the necessary electrical insulation. The insulation is potential-equalizing rather than isolated, maintaining electromagnetic balance.
3Productivity
If automated winding machine is used, then productivity increases, but manual intervention is still required for final arrangement
Solution Approach 1:
The winding process is segmented into two distinct stages: (1) automated winding on a template where coils are pre-assembled into complete phases, and (2) automated drawing-in of the pre-assembled phases into stator slots. This segmentation allows the complex task of achieving correct arrangement to be completed in the first stage under automated control, while the second stage simply requires pulling the pre-arranged coils into position, eliminating the need for manual intervention.
Data Source
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AI summary
The invention relates to a method for winding a two-layer winding (1) intended for a three-phase synchronous or asynchronous machine (3) onto a hollow cylindrical stator (2) in a single winding, comprising the steps of: providing the stator (2) in which a rotor (5) can be inserted in the direction of a stator axis (4), wherein the stator (2) has a plurality N of open slots (6) on its radial inner side, each extending in a radial direction and into each of which a base winding (7) can be inserted as a base in the radial direction on the outside and a top layer winding (8) can be inserted as a top layer in the radial direction on the inside, wherein N = number of holes q * number of poles 2p * phase m, with number of holes q of the stator ≥ 3, number of poles 2p of the stator (2) ≥ 2 and phase m = 3,and successively for each phase m and for each number of pole pairs p: winding of p * q in series of individual coils i of a coil group assigned to the respective phase m with one pole of a pool pair in a slot group (9) of q adjacent slots (6) which adjoins a slot group (9) of the previous phase, and with the other pole of the pool pair in another slot group (9) of q adjacent slots (6) which is arranged by 2 * q slots (6) to the slot group (9), so that after the individual coils i = 1 ... p * q - 2 * k of the series come to lie in pairs first as underlay winding (7) and then as overlay winding (8) in a respective slot (6) of the slot groups (9), the individual coils i = p * q - 2 * k+1 ... p * q - 1 * k come to lie in the remaining underlays of the slot groups (9) and the individual coils i = p * q - 1 * k +1 ... p * q * k come to lie in the remaining upper layers of the groove groups (9) of the previous phase,with step reduction k < q.,