Distributed Stator Winding Pitch Variation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric machine stators with distributed windings face challenges in achieving optimal electrical balance and reducing radial thickness due to complex conductor arrangements and end loop connections, which affect assembly and nesting efficiency.
Innovation Solution
A method of forming conductors into distinct winding pitches and weaving them between poles to create a balanced stator winding, where conductors are nested and connected in specific patterns to improve electrical balance and reduce radial thickness, involving changes in winding pitches and end loop configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductors are arranged in complex patterns to achieve distributed winding, then electrical balance is improved, but radial thickness increases and assembly efficiency decreases
Solution Approach 1:
The stator winding is divided into multiple independent modular units, each containing a specific number of conductor turns (e.g., 2-turn units). These modular units can be independently manufactured and then assembled into the stator, simplifying the overall complexity while maintaining electrical balance through systematic arrangement of these segments.
Solution Approach 2:
Conductors are arranged in a nested configuration where end loops are positioned to nest within the radial space of adjacent conductors. This nesting approach allows complex winding patterns to be achieved while minimizing the overall radial thickness of the stator coil assembly.
2Reliability
If conductors are arranged in complex patterns to achieve distributed winding, then electrical balance is improved, but assembly efficiency decreases
Solution Approach 1:
Conductor units are pre-assembled into modular configurations with predetermined turn counts and end loop arrangements before being installed in the stator. This preliminary preparation of standardized modules significantly improves assembly efficiency while maintaining the electrical balance requirements of distributed windings.
Solution Approach 2:
The invention systematically varies parameters such as the number of turns per module, the arrangement of end loops, and the positioning of conductors within slots to achieve different winding configurations (e.g., 2/3 distributed, 2/4 distributed). This parameter-based approach allows flexible design of electrical balance while maintaining assembly efficiency through standardized modular construction.
3Reliability
If winding pitch is changed to optimize conductor arrangement, then electrical balance is improved, but device complexity increases
Solution Approach 1:
Different winding pitch values are applied locally to specific conductor units or slot positions rather than uniformly across the entire stator. For example, certain modules may use a first winding pitch while adjacent modules use a second winding pitch, allowing optimization of electrical balance for each local region while maintaining overall system manageability.
Data Source
AI summary
A method of forming a stator for an electric machine includes forming a first conductor and a second conductor into a plurality of bends having a first winding pitch, creating a winding layer by introducing the first conductor and the second conductor into a first pole of a stator with the second conductor being on top of the first conductor at a first end loop crossing zone. The winding pitch of the first conductor is changed to a second winding pitch and the winding pitch of the second conductor is changed to a third winding pitch. The first conductor is woven relative to the second conductor between the first pole and a second pole. The first conductor and the second conductor are introduced into the second pole of the stator with the first conductor being on top of the second conductor at a second end loop crossing zone.