Stator Winding Production via Radial Stacking and Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing stator windings in electrical machines, such as three-phase generators for motor vehicles, face challenges with long winding heads due to the need for radial expansion and uneven temperature distribution, and are limited by low electrical filling factors and complex production processes.
Innovation Solution
A method involving the production of a semi-finished winding product with coil arrangements that allow for a two-layer arrangement and a sequencing system with slots, enabling efficient insertion and arrangement of coil sides in a stator, and a winding device that creates star-shaped half-windings for a distributed wave winding, addressing the issues of winding head length and temperature distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If phases are wound individually and drawn in one after the other using traditional drawing-in method, then the winding can be produced in series, but the winding heads become relatively long and temperature distribution becomes uneven
Solution Approach 1:
The patent divides the winding production into separate phases where each phase is wound individually on its own winding head, then drawn in sequentially. This segmentation allows each winding head to be optimized independently and enables parallel processing of different phases, reducing overall production time while maintaining manageable winding head dimensions.
Solution Approach 2:
The patent transitions from a single-layer sequential drawing-in process to a multi-layer arrangement where end coils are stacked radially. This dimensional change from 2D planar arrangement to 3D radial stacking allows shorter winding heads while maintaining the ability to produce multiple phases in series.
2Adaptability or versatility
If end coils are pressed radially outwards to create space for subsequent phases, then space is made for next phases, but winding heads become longer and temperature distribution becomes uneven
Solution Approach 1:
The patent implements a nested arrangement where end coils of different phases are stacked radially one inside another, similar to nested dolls. Each phase's end coil is positioned in a different radial layer, allowing multiple phases to coexist in a compact space without requiring radial expansion that would create temperature gradients.
3Length of stationary object
If six half-phases are wound individually directly into the stator iron, then winding heads can be made shorter, but three switching points (weld points) are visible and production is limited to parallel wire with maximum 35% electrical filling factor
Solution Approach 1:
The patent extracts the switching points and connection operations from the final stator assembly by pre-assembling complete phase windings on winding heads before drawing them in. This separates the complex connection operations from the stator iron, reducing visible switching points and enabling more flexible wire configurations that can achieve higher electrical filling factors.
4Adaptability or versatility
If individual strands and sub-strands are inserted into corresponding slots in multiple steps, then flexibility is increased, but production time and process complexity increase
Solution Approach 1:
The patent performs preliminary assembly of complete phase windings on winding heads before the drawing-in operation. All necessary positioning, shaping, and pre-connections are completed in advance, allowing the actual insertion into stator slots to be done in a single efficient operation rather than multiple incremental steps.
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 2
AI summary
The invention relates to a method for producing a multi-phase winding (83) for a stator of an electric machine by means of a winding device (90). For this purpose, a semi-finished winding product (50) is produced and, in the production of the semi-finished winding product (50), a plurality of phases of the winding (83) are produced and, in the process, two half windings (119, 120, 121, 122, 123, 124) connected electrically in series are produced for each phase of the winding. Each half winding (119, 120, 121, 122, 123, 124) is produced in the form of a winding star by means of winding sub-groups as waves having wave sides (133). The method is characterized in that the half windings (119, 120, 121, 122, 123, 124) of the phases are arranged in a stack in such a way that, in a stacking direction, a first half winding (124) of a first phase is followed directly by a first half winding (122) of another phase and said first half winding of the other phase is followed by a first half winding (120) of a further phase and a first sub-stack is formed by the first half windings (120, 122, 124), a second sub-stack being formed on the first sub-stack in the same stacking direction and a second half winding (123) of the first phase being wound and a second half winding (121) of the other phase being wound directly on the second half winding of the first phase and a second half winding (119) of the further phase being wound directly on the second half winding (121) of the other phase.