Stator Winding Layout for Aggregated Lead Terminals and Insulation
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Solution Overview
Problem
Existing rotating electric machines face challenges in efficiently aggregating external-connection-side lead sections and ensuring insulation and high manufacturing workability, particularly in electric vehicle motors, where lead sections are dispersed and raise manufacturing complexity.
Innovation Solution
The rotating electric machine design aggregates external-connection-side lead sections into one position, reduces raised regions by neutral wire routing, and ensures insulation between conductors through a 2Y distributed winding structure, pairing lead sections perpendicular to the stator core, and using pre-formed neutral wires with obtuse angles to minimize pressure on insulation coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If external-connection-side lead sections are aggregated into one position, then manufacturing efficiency and cable connection ease are improved, but insulation complexity and isolation requirements increase
Solution Approach 1:
The patent divides the stator winding into multiple independent coils, each with its own insulation structure. The lead sections are segmented and routed through separate channels within the slot, with each lead having its own insulation coating and positioning structure, preventing short circuits while maintaining aggregation at the terminal end.
Solution Approach 2:
The patent introduces neutral wires as intermediary elements between the external-connection-side lead sections and the stator core. These neutral wires act as insulating barriers and routing guides, enabling multiple leads to be aggregated in one position while maintaining proper isolation through the mediating neutral wire structure.
2Volume of moving object
If neutral wire routing regions are narrowed, then gap with transmission section is improved, but manufacturing complexity increases
Solution Approach 1:
The patent resolves the space conflict by changing the routing dimension - instead of routing neutral wires horizontally across the slot width, they are routed vertically along the slot depth direction. This dimensional change allows the raised region width to be minimized while still providing adequate routing space for neutral wires along the axial direction.
Solution Approach 2:
The patent nests the neutral wire routing within the existing slot structure, utilizing the slot depth space that would otherwise be unused. The neutral wires are positioned within the slot boundaries, nested among the coil windings, thereby narrowing the external raised region without requiring additional manufacturing complexity.
3Ease of operation
If lead sections are concentrated into one position, then cable connection ease is improved, but isolation structure complexity increases
Solution Approach 1:
The patent merges the isolation function into the neutral wire structure itself. The neutral wires serve dual purposes: electrical connection and physical isolation barrier. By combining these functions into a single integrated component, the lead sections can be concentrated at one position for easy cable connection without requiring separate, complex isolation structures.
Solution Approach 2:
The neutral wires are designed as multi-functional elements that simultaneously provide electrical connection, mechanical support, and insulation isolation. This universal design allows lead sections to be aggregated at one position while maintaining simple isolation through the multi-functional neutral wire structure, avoiding the need for additional dedicated isolation components.
Data Source
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AI summary
A rotating electric machine 3 includes a rotor 4 and a stator 5. The stator coil of the stator 5 includes a set of a first stator coil and a second stator coil that is stored in an adjacent slot to a slot in which the first stator coil is stored, with a number of the set being same as a number of phases, and one end of each of the first stator coil and the second stator coil is a lead section 53, 54, 55 and an other end is a neutral point 56, 57. A plurality of the stator coils are arranged radially in layers in each slot, and a lead section of the first stator coil and a lead section of the second stator coil are connected with each other with one of the lead sections 53, 54, 55 extending from an outermost layer of the slot and an other of the lead sections 53, 54, 55 extending from an innermost layer of the slot so that the connected lead sections 53, 54, 55 constitute an external connection terminal.