Stator Winding Jumper Positioning for Reduced Crowding
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Solution Overview
Problem
The existing segmented winding arrangements in electric machines face challenges with crowding at the connection end of the stator, leading to difficulties in assembly, increased risk of short circuits, and space constraints in compact applications like electric vehicles, which complicates manufacturing and increases costs.
Innovation Solution
A stator winding arrangement with jumpers positioned inside the conductor segments and connected using straight and arc-shaped phase connection members, along with series winding connection loops, to reduce crowding and enhance clearance, allowing for easier assembly and reduced manufacturing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If jumpers are positioned outside the conductor segments at the connection end of the stator, then the connection between conductors can be achieved, but crowding increases and clearance is reduced
Solution Approach 1:
The jumper is repositioned from the traditional external location to extend into the inner cylindrical space of the stator core, utilizing the radial dimension inward toward the rotor. This dimensional shift moves the jumper away from the crowded connection end area while maintaining its electrical connection function between conductor segments.
Solution Approach 2:
The jumper is nested within the inner cylindrical space of the stator core, utilizing the existing internal space rather than adding to the external footprint. This nesting approach allows the jumper to be accommodated within the machine's existing geometry without requiring additional clearance.
2Area of stationary object
If conductors and jumpers are strategically positioned to reduce crowding, then clearance is improved, but assembly complexity increases
Solution Approach 1:
The winding arrangement is segmented into distinct components: conductor segments positioned in slots, jumpers extending into the inner cylindrical space, and connection points at the connection end. This segmentation allows each component to be independently positioned and optimized, simplifying the overall assembly process while maintaining clear clearance.
3Adaptability or versatility
If jumpers are used to connect non-adjacent conductors, then winding connectivity is achieved, but manufacturing difficulty increases
Solution Approach 1:
The jumpers are pre-positioned within the inner cylindrical space before final assembly, with their locations and orientations predetermined. This preliminary positioning simplifies the assembly process by eliminating complex field adjustments and ensuring proper alignment during manufacturing.
Data Source
AI summary
An electric machine a cylindrical stator core having an outer perimeter surface and an inner perimeter surface with a plurality of slots formed between the inner perimeter surface and the outer perimeter surface. The inner perimeter surface defines an inner cylindrical space for the stator that extends in an axial direction within the stator. The stator core is configured to retain a winding arrangement comprised of a plurality of conductor segments positioned in the plurality of slots of the stator core. The winding arrangement further includes a jumper extending into the inner cylindrical space and connecting two of the plurality of conductor segments. Accordingly, the jumper appears as a chord of a circular end shape of the stator core.