Stator Winding Insulation via Inverted Conductor Segment Bends
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Solution Overview
Problem
Existing stator designs for electric rotating machines require significant axial height for electrical insulation between conductor segments, leading to increased coil end height and potential insulation issues.
Innovation Solution
The stator design incorporates first and second conductor segments with outwardly and inwardly oriented bends, respectively, to increase the interval between protrusive ends, allowing for a decreased coil end height while ensuring adequate electrical insulation, and includes third segments with straight protrusive ends for ease of arrangement and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the ends of conductor segments are bent outward to ensure electrical insulation, then the degree of electrical insulation between conductor segments is improved, but the axial height of the coil end increases
Solution Approach 1:
Instead of bending all conductor segment ends in the same outward radial direction, the patent applies opposite bending directions: conductor segments in outer slots are bent outwardly while conductor segments in inner slots are bent inwardly. This inverted approach for inner segments allows the coil end height to be reduced while still maintaining adequate electrical insulation between all adjacent conductor segments through the alternating bend pattern.
2Length of moving object
If the axial height of the coil end is decreased, then the entire axial height of the stator is reduced, but the electrical insulation between conductor segments may be compromised
Solution Approach 1:
The patent applies different bend configurations to conductor segments based on their local positions within slots. Conductor segments in outer slots (further from the stator core center) are bent outwardly, while conductor segments in inner slots (closer to the center) are bent inwardly. This localized differentiation allows each region to contribute to insulation in its own optimal manner, maintaining overall electrical insulation while reducing the maximum axial height required.
3Reliability
If all conductor segment ends are bent outwardly, then electrical insulation is ensured, but the complexity of the winding structure increases
Solution Approach 1:
The patent introduces asymmetry into the winding structure by bending conductor segments in opposite radial directions depending on their slot position. Rather than a uniform symmetric bend pattern, the asymmetric configuration (outward bends for outer segments, inward bends for inner segments) creates a more compact overall structure that reduces coil end height while maintaining insulation through the deliberate asymmetric arrangement.
Data Source
AI summary
A stator for an electric rotating machine is provided which includes a stator winding made up of a plurality of conductor segments. Each of the conductor segments has a leg which includes an in-slot portion into one of slots of a stator core and a protrusive end extending outside the slot. The protrusive ends of the conductor segments are welded together to form a stator winding. The conductor segments are broken down into first conductor segments and second conductor segments. The protrusive ends of the first and second conductor segments include outwardly-oriented bends and inwardly-oriented bends for increasing an interval between every pair of adjacent two of the protrusive ends to be welded, thus ensuring a required degree of electrical insulation between the pairs of the protrusive ends and permits the height of a coil end of the stator winding to be decreased.