Continuous Stator Winding Layout for MMF Balance and Simpler Forming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional motor winding techniques face inefficiencies and increased error rates due to complex winding patterns required for achieving MMF balance among parallel windings, necessitating multiple machines and processes, which complicate the manufacturing process.
Innovation Solution
A continuous winding assembly using standard pitches for both first and second winding portions, with terminal connections that simplify the coil forming process and minimize errors, while maintaining MMF balance through a series circuit configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex winding patterns with non-standard pitches are used to achieve MMF balance among parallel windings, then MMF balance is improved, but device complexity and manufacturing difficulty increase significantly
Solution Approach 1:
The invention changes the pitch parameter from non-standard to standard pitch (e.g., 10 slots/pole) while maintaining MMF balance through a different configuration approach. By using standard pitch consistently across all parallel windings and adjusting the winding layout pattern, the invention achieves the same MMF balance effect without the complexity of varying non-standard pitches.
Solution Approach 2:
Instead of achieving MMF balance by varying the pitch of each winding (conventional approach), the invention inverts the approach by using uniform standard pitch for all windings and achieving balance through the overall winding configuration and layer arrangement. This reverses the problem-solving strategy from parameter variation to configuration optimization.
2Reliability
If complex winding patterns are used to achieve MMF balance, then MMF balance is improved, but manufacturing efficiency and productivity decrease due to requiring multiple machines and processes
Solution Approach 1:
By standardizing the pitch parameter to a common value (standard pitch), the invention enables all parallel windings to be manufactured using the same coil forming process and equipment. This eliminates the need for multiple specialized machines required by non-standard pitch variations, thereby improving productivity while maintaining MMF balance through the standardized configuration.
Solution Approach 2:
The invention makes a single coil forming process universal for all parallel windings by using standard pitch. One type of winding configuration can serve multiple parallel circuits, eliminating the need for different forming processes for each winding type and significantly improving manufacturing efficiency.
3Reliability
If complex winding patterns are used to achieve MMF balance, then MMF balance is improved, but manufacturing errors and defects increase due to increased likelihood of operational mistakes
Solution Approach 1:
By changing from non-standard to standard pitch, the invention simplifies the winding pattern to a repeating, predictable sequence that is easier to execute accurately. Standard pitch creates regular intervals and symmetrical arrangements that reduce the cognitive load on operators and minimize mistakes during the winding process.
Solution Approach 2:
The invention uses uniform standard pitch across all windings, creating homogeneous and consistent winding patterns. This homogeneity makes the manufacturing process more predictable and easier to control, reducing variability and errors compared to heterogeneous non-standard pitch patterns.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A continuous winding assembly, being applied to a stator including slots having a plurality of slot groups and arranged in a consecutive position with a slot group per rotor pole, comprising: a first winding portion including a plurality of first wires (110, 120) having a first pitch, the continuous first wires (110, 120) pass through the plurality of slot groups; a second winding portion including a plurality of second wires (210, 220) having said first pitch, t the continuous second wires (210, 220) pass through the plurality of slot groups carrying said first wires, the plurality of second wires (210, 220) being stacked on a radially outer side of the slots of said first wires; and a terminal portion (300) electrically connecting at least two of the plurality of first wires (110,120) of the first winding portion and the plurality of second wires (210, 220) of the second winding portion.