Stator Winding Layout With Nested End Turns for Compact Balance
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Solution Overview
Problem
Creating an electrically balanced stator winding for electric machines that is compact and easily formed is challenging, as existing methods are time-consuming and inefficient, especially when trying to introduce windings into laminations with reduced thickness.
Innovation Solution
A multi-conductor winding system where conductors with identical wire forms are arranged in specific orientations, with end turns having distinct pitches, allowing for nested conductor pairs that reduce thickness and improve electrical balancing by interleaving windings within the stator core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional winding methods are used to form stator windings, then the windings can be introduced into laminations, but the process is time-consuming and challenging
Solution Approach 1:
The winding is divided into multiple discrete conductors (first conductor, second conductor, third conductor, fourth conductor) that can be independently formed and then assembled. Each conductor is formed with specific slot segments and end turns that can be separately prepared and then combined within the lamination slots, enabling parallel processing and reducing overall manufacturing time
Solution Approach 2:
The conductors are pre-formed with their slot segments and end turns configured before insertion into the lamination. The wire form is shaped in advance to include the necessary bends and configurations (such as 180-degree bends and nested arrangements) so that when inserted, the windings are already in their final balanced configuration, eliminating time-consuming on-site forming operations
2Length of stationary object
If the stator thickness is reduced for more compact designs, then the machine size is decreased, but forming and introducing windings becomes more challenging
Solution Approach 1:
The conductors are arranged in a nested configuration where end turns of one conductor are positioned within the space occupied by end turns of adjacent conductors. Specifically, the first end turn of the first conductor nests with the second end turn of the second conductor, and the third end turn of the third conductor nests with the fourth end turn of the fourth conductor. This nesting reduces the overall thickness required for the winding assembly, enabling compact stator designs while maintaining proper winding formation
Solution Approach 2:
The winding arrangement utilizes three-dimensional spatial positioning within the lamination slots, with conductors positioned at different heights and orientations. The nested arrangement creates vertical layering within the slot depth, allowing multiple conductors to occupy the same horizontal footprint at different vertical levels, thereby reducing the required stator thickness
3Loss of energy
If conductors are arranged in mirror image orientations with nested end turns, then electrical balance is improved and losses are minimized, but the device complexity increases
Solution Approach 1:
The conductors are arranged in mirror image orientations where the first conductor and second conductor have asymmetric positions relative to the lamination centerline, as do the third and fourth conductors. This asymmetric arrangement creates balanced magnetic paths and ensures that the winding configuration produces uniform magnetic flux distribution, minimizing harmonic losses and improving electrical efficiency
Solution Approach 2:
Different portions of the winding structure are given different properties: the slot segments are positioned at specific locations within the lamination slots, the end turns are configured with specific nest arrangements, and the conductors are oriented at different angles. This local differentiation of properties ensures optimal electrical balance and loss minimization in each region of the stator
Data Source
AI summary
A multi-conductor winding for an electric machine includes a plurality of conductors having a substantially identical wire form with a plurality of end turns joining a plurality of slot segments. A first portion of the plurality of conductors is arranged in a first orientation and a second portion of the plurality of conductors is arranged in a second orientation that is a mirror image of the first orientation. The plurality of end turns of the plurality of conductors includes at least three distinct winding pitches.