Stator Winding Reduces Conductor Types via Pitch Variation
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Solution Overview
Problem
The existing stator designs for electric machines with polyphase windings require a large number of different conductor elements, particularly special connectors, which increase manufacturing costs.
Innovation Solution
The stator design reduces the number of different conductor elements by using lower and upper conductor elements with specific pitches and layer arrangements, including center conductor elements, to form a repeating sequence of conductor connections, resulting in a symmetric and uniformly constructed polyphase winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a large number of different conductor elements including special connectors are used to form the polyphase winding, then the winding configuration can be achieved, but the manufacturing costs increase
Solution Approach 1:
The patent applies homogeneity by using only two types of conductor elements (lower conductor elements and upper conductor elements) throughout the entire polyphase winding, replacing the traditional approach that required multiple different conductor types including special connectors. This standardization reduces manufacturing complexity and cost while maintaining the required winding configuration through systematic arrangement of these homogeneous elements with different pitches
Solution Approach 2:
The patent segments the conductor elements into two distinct categories: lower conductor elements with pitch p and upper conductor elements with pitch p+1. Each type has specific characteristics and positions, but together they form a complete winding system. This segmentation allows the complex winding to be constructed from simple, repeatable units, reducing the need for special connectors
2Device complexity
If fewer different conductor elements are used to reduce manufacturing costs, then the device complexity decreases, but it becomes difficult to achieve a symmetric and uniformly constructed end winding
Solution Approach 1:
The patent intentionally introduces asymmetry in the pitch values between lower conductor elements (pitch p) and upper conductor elements (pitch p+1). This controlled asymmetry, when combined with the systematic arrangement of conductor elements in specific layers and positions, actually produces symmetric and uniform end windings. The different pitches create the necessary geometric variation to achieve uniformity in the final winding configuration
Solution Approach 2:
The patent employs periodic action through repeating sequences of lower and upper conductor elements arranged in specific patterns. The conductor elements are positioned in repeating sequences around the stator, with lower elements in bottom layers and upper elements in top layers. This periodic arrangement ensures symmetry and uniformity across all end windings while using only two types of conductor elements
3Productivity
If conductor elements with different pitches are used to create repeating sequences, then the polyphase winding configuration is optimized, but the arrangement complexity increases
Solution Approach 1:
The patent optimizes the polyphase winding configuration by changing the pitch parameter of conductor elements. Lower conductor elements have pitch p while upper conductor elements have pitch p+1. This parameter variation allows the creation of repeating sequences that efficiently form the polyphase winding, improving productivity while maintaining manageable arrangement complexity through systematic rules
Data Source
AI summary
Stators for an electrical machine which are fitted with a polyphase winding which is in the form of a plug-type winding and the winding sections of which run through slots of the stator and comprise a plurality of different conductor elements are already known. At least some of the said conductor elements have in each case two conductor limbs and in each case one connecting conductor which connects the two conductor limbs, wherein an even number of n conductor limbs is arranged one above the other in the radial direction with respect to a stator axis in each slot. Each conductor limb of one of the conductor elements is provided in its slot in a specific position with respect to a slot base of the slot. These polyphase windings comprise a comparatively large number of different conductor elements, in particular so-called special conductors which differ from the standard conductor elements. These special conductors increase the manufacturing costs. In the case of the stator according to the invention, a few different conductor elements are provided for the polyphase winding. According to the invention, it is provided that the lower conductor elements (5) each have conductor limbs (5.1) which are situated in the same position and the upper conductor elements (6) each have conductor limbs (6.1) which are situated in the same position, wherein the step width of the lower conductor elements (5) in relation to the step width of the upper conductor elements (6) differs by the value of one, in particular is greater by the value of one.