Stator Winding Intermediate Conductor Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production method for high-power-density electric machine stators, such as those for motor vehicles, is inflexible, leading to reduced design space for the rotor winding, which results in inefficient power usage and the need for costly reinforcing components due to the conical configuration of rotor winding heads.
Innovation Solution
The use of an intermediate conductor that connects conductor sections in series, arranged radially within the winding support, allows for additional design space for the rotor by utilizing the space beyond the rotor winding head, avoiding the conical configuration and enabling efficient use of existing manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the connection section is guided at a smaller radius to switch between parallel and series connection, then adaptability of the production line is improved, but the design space for the rotor is reduced
Solution Approach 1:
An intermediate conductor is introduced as a mediator component to connect the first and second conductor sections. This intermediate conductor is arranged radially within the connection sections and allows the switching between parallel and series connections without requiring the connection sections to be guided at a smaller radius, thereby preserving the rotor design space while maintaining production line adaptability.
Solution Approach 2:
The intermediate conductor is arranged in a radial dimension within the connection sections, utilizing the radial space within the winding support. This dimensional arrangement allows the connection switching function to be achieved without compromising the axial design space required for the rotor winding head.
2Adaptability or versatility
If the rotor winding head is configured conically to accommodate reduced design space, then adaptability to the constrained space is improved, but manufacturing cost increases
Solution Approach 1:
The intermediate conductor serves as an intermediary that enables series connection of conductor sections without requiring conical configuration of the rotor winding head. This maintains the standard cylindrical design of the rotor, avoiding the need for complex conical machining and associated reinforcing components, thereby reducing manufacturing costs while achieving the desired connection adaptability.
3Reliability
If the connection section is twisted by a defined angle concentrically to the stator axis, then electrical connection reliability is improved, but the production process becomes inflexible
Solution Approach 1:
The conductor is segmented into multiple conductor sections (first and second conductor sections) that can be independently processed and then connected via the intermediate conductor. This segmentation allows each section to be twisted by the defined angle for reliable electrical connection, while the modular structure enables flexible production processes including switching between parallel and series connections using the same production line.
Data Source
AI summary
A stator for an electric machine comprises a winding support having multiple grooves and at least one conductor forming a respective winding for a respective phase of the stator, wherein a first and second conductor section of the conductor are formed respectively by multiple conductively interconnected conductor clips, wherein the conductor clips comprise respectively two groove sections, each being led through one of the grooves of the winding support, a coupling section connecting the groove sections, and two connection sections which protrude beyond the grooves on the side of the winding support situated opposite the coupling section, wherein the first and second conductor section are connected to each other in series by an intermediate conductor, wherein the intermediate conductor conductively connects exclusively one connection section of a conductor clip of the first conductor section to a connection section of a conductor clip of the second conductor section and is arranged radially within the connection sections on the side of the winding support situated opposite the coupling section.