Electric Machine Stator Winding Head Connection Line Fixation
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Solution Overview
Problem
Stators for electric machines face challenges in securely fastening winding connection lines, which can lead to damage during assembly and operation, often requiring additional fixing means like binding cords or wires, and result in larger manufacturing tolerances and less compact installation dimensions.
Innovation Solution
The stator design features a winding head with radially outward and inward sets of winding portions that restrict the freedom of movement of connection lines, eliminating the need for additional fastening means and allowing for secure fixation through sewing, tying, adhesive bonding, or potting, while maintaining a compact axial height and high copper filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional fastening means like binding cords or wires are used to secure winding connection lines, then the reliability of the stator assembly is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The winding connection lines are integrated into the winding head structure itself, merging the function of electrical connection with the mechanical support function. The connection lines are arranged to run between the first and second sets of winding portions, which act as built-in support structures, eliminating the need for separate binding cords or wires.
Solution Approach 2:
The winding portions themselves provide the support and positioning function for the connection lines. The first set of winding portions arranged radially outwardly and the second set arranged radially inwardly create a self-contained structure that naturally supports the connection lines without requiring external fastening means.
2Reliability
If winding connection lines are securely fastened using additional means, then the risk of wire damage during assembly and operation is reduced, but the manufacturing time and productivity are decreased
Solution Approach 1:
The winding portions are pre-formed during the winding process to create the support structure for the connection lines. The first and second sets of winding portions are created as integral parts of the winding head, so that when connection lines are later installed, they are already positioned in a protected configuration without requiring additional fastening steps.
3Reliability
If the stator design accommodates additional fastening means, then the security of connection lines is improved, but the axial height and installation dimensions increase
Solution Approach 1:
Instead of adding axial height to accommodate fastening means, the solution uses the radial dimension to create support structures. The first set of winding portions is arranged radially outwardly and the second set radially inwardly, creating a radial support structure that secures connection lines without increasing the axial height of the stator.
Data Source
AI summary
The invention relates to a stator (100) for an electric machine having a stator core (102) and at least one winding (110) which has a winding head (120) protruding axially beyond the stator core (102), wherein the winding head (120) comprises portions of the winding which form reversals of the winding wires, winding connection lines (126) for energizing the winding (110) and at least one radially outwardly arranged first set of winding portions (127) and one radially inwardly arranged second set of winding portions (128) spaced apart from the first set, wherein the portions of the winding connection lines (126) each run in the circumferential direction, do not protrude axially beyond the first (127) and the second (128) sets of winding portions and are arranged radially between and fixed by the first (127) and the second (128) sets of winding portions. The invention also relates to a method for producing such a stator (100) and to an electric machine having such a stator (100).