Stator Winding Jumper Wire Arrangement for Insulation
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Solution Overview
Problem
In rotating electric machines, the configuration of stator windings leads to increased potential differences between phases, degrading insulation due to adjacent power and neutral wires, resulting in inadequate insulation and potential electrical breakdown.
Innovation Solution
The stator design incorporates a jumper wire structure where 5-pitch and 7-pitch jumper wires overlap for two phases and are spaced for the remaining phase, ensuring power-wire partial windings are adjacent to identical or neutral-wire partial windings, reducing potential differences and enhancing insulation. Additionally, neutral-line connection portions and bus bars are used to simplify wiring and reduce current density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If power-wire partial windings and neutral-wire partial windings are adjacent to each other in the stator winding configuration, then the insulation is degraded due to increased potential differences, but the wiring structure becomes simpler
Solution Approach 1:
The patent applies local quality by differentiating the arrangement of jumper wires for different phases. Specifically, for two phases (e.g., U and W phases), 5-pitch and 7-pitch jumper wires are arranged to overlap, while for the remaining phase (V phase), two 5-pitch jumper wires are spaced apart. This localized differentiation in wiring arrangement ensures that power-wire partial windings are positioned adjacent to identical or neutral-wire partial windings rather than adjacent phases, thereby reducing potential differences and improving insulation reliability without significantly increasing overall wiring complexity
Solution Approach 2:
The patent implements equipotentiality by strategically arranging jumper wires to position power-wire partial windings adjacent to identical or neutral-wire partial windings. This arrangement reduces the potential difference between adjacent windings, as identical or neutral wires have similar or equal potentials. By creating equipotential or near-equipotential adjacent regions, the insulation stress is reduced, preventing electrical breakdown while maintaining a relatively simple wiring structure
2Reliability
If multiple jumper wires are used to rearrange the wiring configuration, then the insulation is enhanced by reducing potential differences, but the device complexity increases
Solution Approach 1:
The patent applies local quality by differentiating the arrangement of jumper wires for different phases. Specifically, for two phases (e.g., U and W phases), 5-pitch and 7-pitch jumper wires are arranged to overlap, while for the remaining phase (V phase), two 5-pitch jumper wires are spaced apart. This localized differentiation in wiring arrangement ensures that power-wire partial windings are positioned adjacent to identical or neutral-wire partial windings rather than adjacent phases, thereby reducing potential differences and improving insulation reliability without significantly increasing overall wiring complexity
Solution Approach 2:
The patent applies partial action by implementing the differentiated jumper wire arrangement only for specific phases rather than uniformly for all three phases. By applying the overlapping arrangement to two phases and the spaced arrangement to one phase, the patent achieves the insulation improvement goal with a modified but not completely redesigned wiring structure, balancing reliability enhancement with acceptable device complexity
Data Source
AI summary
Each of phase windings includes parallel windings for each phase connected together in parallel, and the parallel windings include power-wire partial windings connected to a power supply side, neutral-line partial windings connected to a neutral point, and at least one of a set of 5-pitch and 7-pitch jumper wires, the power-wire partial windings, the neutral-wire partial windings, and the jumper wires being included in the plurality of partial windings forming the parallel windings. For two of the three phases, each of the 5-pitch jumper wires and a corresponding one of the 7-pitch jumper wires overlap each other, and for the remaining single phase, two of the 5-pitch jumper wires are spaced from each other in the circumferential direction, and each of the power-wire partial windings is adjacent to another power-wire partial winding for an identical phase or to a corresponding one of the neutral-line partial windings for a different phase.