Stator Winding Layout for Lower Heat in Switched Wire Connections
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Solution Overview
Problem
Existing stator designs fail to effectively manage heat generation in switched connection states of winding wires, particularly in multi-phase configurations where the connection states of first and second winding wires are switched, leading to inefficiencies in heat dissipation.
Innovation Solution
A stator design featuring a stator core with alternating tooth portions and slots, where the first and second winding wires have different coating thicknesses and cross-sectional areas, with the second winding wire having a thinner coating and larger cross-sectional area to reduce heat generation and electrical resistivity, while maintaining insulation and power efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the second winding wire has the same coating thickness as the first winding wire, then insulation is maintained, but heat generation is not reduced
Solution Approach 1:
The patent applies different coating thicknesses to different winding wires based on their specific operational requirements. The second winding wire has a thinner coating (0.01-0.05mm) compared to the first winding wire (0.05-0.1mm), optimizing heat dissipation for the second wire while maintaining adequate insulation where needed. This local differentiation resolves the contradiction between heat reduction and insulation maintenance.
2Loss of energy
If the second winding wire has a larger cross-sectional area, then electrical resistivity is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent changes key parameters of the winding wires, specifically the cross-sectional area and coating thickness. The second winding wire has a larger cross-sectional area (reducing electrical resistivity) and thinner coating compared to the first winding wire. These parameter changes are implemented within standard manufacturing capabilities, resolving the contradiction between energy loss reduction and manufacturing ease.
3Loss of energy
If both winding wires have the same structure, then manufacturing is simplified, but heat management efficiency is reduced
Solution Approach 1:
The patent implements different structural characteristics for the first and second winding wires. The second winding wire features a thinner coating and larger cross-sectional area optimized for heat dissipation, while the first winding wire has a thicker coating. This local structural differentiation improves heat management efficiency while maintaining overall device simplicity through consistent design principles across different wire types.
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 design effectively reduces heat generation and power loss in the second winding wire, ensuring efficient operation in both energized states, thereby minimizing total heat and power loss across the stator.
Implementation Method 1
amounts of heat that is generated on the first winding wire and the second winding wire whose connection states are switched are not taken into consideration
Implementation Method 2
a thickness of the second coating portion is smaller than a thickness of the first coating portion
Data Source
AI summary
A stator includes a stator core and a coil. The coil includes at least a first winding wire and a second winding wire, and connection states of the first winding wire and the second winding wire are switched. The first winding wire includes a first insertion portion that passes through a slot. The second winding wire includes a second insertion portion that passes through the slot through which the first insertion portion passes. Both the first insertion portion and the second insertion portion are disposed in the same slot. The first insertion portion includes a first core wire and a first coating portion that covers the first core wire. The second insertion portion includes a second core wire and a second coating portion that covers the second core wire. A thickness of the second coating portion is smaller than a thickness of the first coating portion.