Stator Winding Layout to Prevent Loop Currents in Motors
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Solution Overview
Problem
The existing wave-winding mode in motor stator modules leads to high production costs, difficulty in manufacturing, and a high risk of breakdown due to voltage differences between layers, resulting in loop current phenomena and motor failure.
Innovation Solution
A stator module design with a specific winding pattern and conductor segments that optimize the placement of lead lines and star point lines at the welding end, reducing the risk of loop currents by balancing potential differences and suppressing angular phase differences, thereby preventing motor failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wave-winding mode is used for stator module manufacturing, then the manufacturing process can be simplified, but the production cost increases and manufacturing difficulty arises due to many welding spots and difficult flat wire fastening
Solution Approach 1:
The patent divides the stator winding into multiple independent coil groups, each with controlled voltage potential. By segmenting the winding structure into discrete coils with specific connection patterns, the complex wave-winding is broken down into manageable units that can be manufactured and assembled more easily, reducing the overall manufacturing complexity despite multiple welding spots.
Solution Approach 2:
The patent implements equipotential connections by ensuring that coils at the same potential level are properly connected and isolated from different potential levels. This creates equipotential zones within the stator winding, preventing voltage differences between adjacent layers and eliminating the need for complex insulation and welding arrangements, thereby simplifying the manufacturing process.
2Ease of manufacture
If wave-winding mode is used for stator module manufacturing, then the winding structure can be formed, but manufacturing precision deteriorates due to difficulty in accurately fastening flat wire after paying-off
Solution Approach 1:
The patent employs preliminary positioning structures and pre-prepared coil forms that guide the flat wire into the correct position during the winding process. By preparing the winding path and fastening points in advance, the precision of flat wire fastening is improved, eliminating the difficulties associated with accurate positioning during wave-winding manufacturing.
3Ease of manufacture
If wave-winding mode is used for stator module manufacturing, then the stator winding can be constructed, but reliability decreases due to high voltage difference between layers causing breakdown and short circuit
Solution Approach 1:
The patent implements equipotential connections by ensuring that coils at the same potential level are properly connected and isolated from different potential levels. This creates equipotential zones within the stator winding, preventing voltage differences between adjacent layers and eliminating breakdown and short circuit risks, thereby significantly improving motor reliability.
4Productivity
If wave-winding mode is used for stator module manufacturing, then the winding can be completed, but production cost increases due to many types of flat wire armatures needed
Solution Approach 1:
The patent designs a universal coil structure that can be used across different motor configurations by varying only the connection patterns and coil parameters. This multi-functional coil design eliminates the need to manufacture multiple types of flat wire armatures for different applications, reducing production costs while maintaining productivity through standardized manufacturing processes.
Data Source
AI summary
A stator module is applicable to a motor. The motor comprises z slots, 2p poles, and m phases, where z, p, and m are integers. The stator module includes a stator core and a stator winding. The stator core has multiple stator slots, and the stator slots are distributed in a circumferential direction of the stator core. The stator winding includes a first-class conductor segment, a second-class conductor segment, and a third-class conductor segment. A pitch between a first in-slot portion and a second in-slot portion of the first-class conductor segment is (y−1) stator slots, a pitch between a first in-slot portion and a second in-slot portion of the second-class conductor segment is y stator slots, and a pitch between a first in-slot portion and a second in-slot portion of the third-class conductor segment is (y+1) stator slots, where y is an integer and y=z/2p.