Stator Winding Coil Series Joint Layout for Heat and Resistance
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Solution Overview
Problem
Existing rotary electric machines face challenges in minimizing electrical and thermal resistance in winding coils, which affects heat removal efficiency.
Innovation Solution
The winding coils are connected in series with a joint positioned closer to the axial end surface, forming first and second portions that are connected end-to-end, reducing electrical resistance and enhancing heat dissipation through a series connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the joint connecting first and second portions of winding coils is positioned at the axial end surface, then the electrical resistance is minimized, but the thermal resistance increases and heat removal efficiency decreases
Solution Approach 1:
The patent applies local quality by creating two distinct joint configurations: a first joint connecting first portions of coils positioned at the axial end surface for minimal electrical resistance, and a second joint connecting second portions of coils positioned at an intermediate axial location for optimal thermal contact with cooling structures. This localized differentiation allows each joint to optimize for its specific function (electrical vs. thermal).
Solution Approach 2:
The patent segments the winding coil connections into two separate joint locations along the axial direction. The first joint is separated from the second joint axially, allowing independent optimization of electrical and thermal properties at different locations. This segmentation resolves the contradiction by distributing the electrical and thermal functions to different spatial locations.
2Temperature
If cooling structures are added to provide direct contact with winding coils, then heat removal efficiency improves, but device complexity increases
Solution Approach 1:
The patent merges the cooling function with the existing slot structure by positioning cooling structures within the slots to contact the second portions of the winding coils. This integration allows heat removal without adding separate, complex cooling systems, as the slot structure serves dual purposes: mechanical support and thermal management.
3Reliability
If winding coils are connected in series with joints spaced closer to the axial end surface, then electrical resistance decreases, but the number of joints and connection points increases
Solution Approach 1:
The patent maintains continuous electrical connection through the winding coils by using the first joint at the axial end surface, ensuring minimal interruption of current flow and reduced electrical resistance. The series connection of first and second portions through properly positioned joints ensures continuous electrical action throughout the coil assembly.
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 configuration reduces electrical resistance and improves heat removal efficiency by positioning the joint closer to the axial end surface, thereby optimizing thermal and electrical performance.
Implementation Method 1
it is desirable to interconnect the winding coils in a manner that minimizes electrical and/or thermal resistance therethrough
Implementation Method 2
The heat can be removed using a fluid such as air or a liquid... provide more direct contact with the winding coils and thereby more effectively remove heat generated therefrom
Data Source
AI summary
A rotary electric machine includes a stator extending along an axis and having teeth arranged about the axis. The teeth are circumferentially spaced apart by slots. Winding coils extend around the teeth and through the slots. The winding coils are electrically connected to one another to form phases. At least one of the winding coils has a first portion extending through first and second slots of the slots and including first end turns extending between the first and second slots over an axial end surface of the teeth. A second portion extends through the first and second slots and includes second end turns extending between the first and second slots over the axial end surface of the teeth. The first and second portions are connected in series at a third end turn spaced closer to the axial end surface than either the first or second end turns.