Stator Winding Method Using Rectangular Wire for High Slot Fill Factor
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Solution Overview
Problem
Current motor stator winding methods face challenges in achieving high torque output and compactness, especially with rectangular wires, which have large cross-sectional areas and are difficult to bend, requiring a novel winding manner to optimize slot fill factor and motor performance in limited spaces.
Innovation Solution
A stator winding method involving a first wire positioned in a first direction according to a first rule, then in a second direction according to a second rule, repeating until it fills M layers without crossing, using a rectangular or square cross-section wire to achieve a compact and non-crossing winding structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If rectangular wires are used to increase slot fill factor, then the slot fill factor is improved, but the wire becomes difficult to bend and requires complex winding structure
Solution Approach 1:
The wire is divided into multiple segments with different orientations. Each segment is positioned in a specific direction (first direction for some segments, second direction for others) to collectively fill the slot space efficiently while maintaining manufacturability through modular segmentation
Solution Approach 2:
The winding structure transitions from traditional single-direction layering to multi-dimensional arrangement by introducing both first direction and second direction segments, creating a three-dimensional spatial configuration that maximizes slot fill factor
2Power
If traditional winding methods are used, then the winding process is simple, but the motor cannot achieve high torque output in limited space
Solution Approach 1:
Different regions of the winding adopt different directional orientations. The first direction segments and second direction segments are strategically placed in specific slots and layers to optimize local magnetic field distribution and torque generation in different parts of the motor
Solution Approach 2:
The winding structure employs nested layering where multiple layers of wire segments are arranged in ascending and descending order, with each layer fitting within the spatial constraints of the slot while contributing to the overall torque output
3Quantity of substance
If wire layers are increased to improve performance, then the slot fill factor is improved, but the wire may cross itself causing manufacturing defects
Solution Approach 1:
The winding pattern employs asymmetric directional arrangement where the first direction and second direction segments are not uniformly distributed but strategically positioned to prevent crossing. The asymmetric layout ensures that wire paths in different layers do not intersect while maximizing space utilization
Data Source
AI summary
One or a plurality of embodiments of the present application provide a winding method for a stator winding. The method comprises positioning a first wire in a first direction according to a first rule, wherein the first rule is continuously positioning the first wire from a first layer in the first direction at a spacing of R slots in a layer number ascending manner until passing through an Mth layer; in the Mth layer, subjecting the first wire to pass a first same-layer transition and pass through a next slot having a spacing of R; positioning the first wire in a second direction according to a second rule, wherein the second rule comprises positioning the first wire at the spacing of R slots in a layer number descending manner until passing through the first layer; and in the first layer, subjecting the first wire to pass a second same-layer transition and pass through a next slot having the spacing of R, wherein the first wire advances in the same direction in the first same-layer transition and the second same-layer transition; and advancing the first wire by repeating following the first rule, passing the first same-layer transition, following the second rule, and passing the second same-layer transition until the first wire fills up the M layers of the stator without crossing itself, where M is a total number of layers of the first wire in stator slots.