Stator Winding Pull-In for High Fill Factor Layer Windings
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for inserting stator windings into electric machine stator lamination stacks result in reduced fill factors, increased electrical voltages, and high insertion forces, often damaging wire insulation, and are either complex and expensive or produce jumble windings with crossovers.
Innovation Solution
A method and tool for winding and inserting stator windings as layer windings using a winding tool with adjustable end parts and guide surfaces, allowing windings to be aligned and inserted efficiently into tapered slots, maintaining a defined arrangement and minimizing friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If windings are pulled into stator slots via slot gaps using conventional methods, then the windings can be inserted, but the fill factor is reduced and electrical voltages between adjacent turns increase
Solution Approach 1:
The windings are pre-assembled on a winding tool with defined turn arrangement before insertion into the stator slots. This preliminary preparation ensures that the windings maintain their structured arrangement during the pulling-in process, achieving layer windings with optimized fill factor without requiring complex insertion mechanisms
Solution Approach 2:
The winding tool is divided into multiple tool slots that correspond to individual stator slots. Each tool slot holds a specific phase winding with defined turn arrangement, allowing systematic insertion while maintaining the structured layer winding configuration throughout the process
2Ease of manufacture
If conventional pulling methods are used to insert windings into tapered slots, then insertion can be achieved, but high forces are required that may damage wire insulation
Solution Approach 1:
The winding tool is designed with movable end parts that can be displaced relative to each other along the tool axis. During insertion, the end parts move dynamically to guide the windings through the tapered slot geometry, distributing insertion forces evenly and preventing damage to wire insulation while maintaining reliable connection
3Manufacturing precision
If a needle winder is used to achieve layer windings directly in stator slots, then defined turn arrangement is achieved, but the process becomes considerably more complex and expensive
Solution Approach 1:
A winding tool with structured tool slots serves as an intermediary device between the winding process and the stator slots. The tool slots provide the defined turn arrangement and layer winding structure, while the movable end parts enable easy insertion. This intermediary approach achieves precise turn arrangement without requiring complex needle winders, simplifying the overall manufacturing process
Data Source
AI summary
Disclosed is a method for pulling a stator winding system of an electric machine into a stator lamination stack of the electric machine and to a winding tool, with the stator lamination stack having stator grooves which run parallel to a rotation axis of the electric machine and are distributed in a circle around the rotation axis and open thereto and which have on an end facing the rotation axis a gap region which is narrowed relative to the rest of the stator groove. Windings are arranged in the stator grooves, and winding overhangs, as seen in the direction of the rotation axis, protrude from the stator lamination stack at the two axial ends thereof, with the windings formed in the stator grooves as laid windings. The stator lamination stack has no guide structures on the two axial ends for guiding the individual turns of the windings.