Multi-Path Stator Winding Layout With Reduced End Overhang
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Solution Overview
Problem
Existing stators for electric machines, particularly in automotive applications, face challenges in providing multiple winding paths that can be connected in parallel or series while maintaining symmetry, minimizing axial winding overhang, and facilitating automated manufacturing with high reliability, especially when using flat shaped conductors at high frequencies.
Innovation Solution
A stator design with a stator core having a specific arrangement of slots and shaped conductors, where each phase has multiple paths connected in series or parallel, with connectors providing offset in both radial and circumferential directions to achieve symmetry and reduce winding overhang, allowing for efficient automated production using a limited variety of connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple winding paths are provided for parallel or series connection, then the electrical performance and adaptability are improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The stator winding is segmented into multiple independent paths (first path, second path, etc.) that can be configured in series or parallel. Each path contains multiple phases (U, V, W) with distinct winding sequences, allowing flexible electrical connections while maintaining manageable structural complexity through modular segmentation.
Solution Approach 2:
The patent employs asymmetric winding distributions within each path, where different paths have different numbers of phases and winding configurations. For example, the first path may have three phases while the second path has a different configuration, creating asymmetric structures that enable versatile connection options while resolving the complexity through intentional asymmetry rather than symmetric repetition.
2Loss of energy
If flat shaped conductors are used with high number of layers per slot, then the frequency losses are reduced, but the manufacturing complexity and connection difficulty increase
Solution Approach 1:
The shaped conductors are pre-formed with specific geometries and connection points before assembly into the stator slots. The conductors are manufactured with predetermined shapes that facilitate their insertion and connection, performing the complex shaping operation in advance rather than during assembly, thereby reducing manufacturing complexity while enabling high-layer configurations with flat conductors.
3Shape
If connectors with offset in radial and circumferential directions are used, then the symmetry and winding overhang reduction are improved, but the connector variety and device complexity increase
Solution Approach 1:
The patent employs connectors that serve multiple functions: they provide electrical connections between conductors, establish the required offsets in both radial and circumferential directions, and maintain symmetry across different winding paths. By designing connectors with multi-functionality, the patent reduces the need for numerous specialized connector types, thereby managing device complexity while achieving the desired geometric outcomes.
Solution Approach 2:
The connectors introduce offsets in two dimensions (radial and circumferential directions) simultaneously, transitioning from single-dimensional positioning to two-dimensional spatial arrangement. This dimensional approach enables compact winding configurations with reduced overhang while maintaining symmetry, as the dual-offset connectors systematically position conductors in both radial layers and circumferential slots.
4Productivity
If automated manufacturing process is implemented, then the productivity is improved, but the manufacturing precision and reliability requirements increase
Solution Approach 1:
The winding structure is segmented into standardized modules (paths, phases, and connector units) that can be assembled through automated processes. Each segment has defined geometric and electrical characteristics, enabling robotic manipulation and precise positioning. The modular segmentation allows automated assembly while maintaining high precision through repeatable module replication.
Solution Approach 2:
The patent employs standardized connector designs with fixed offset parameters (specific radial and circumferential offsets) that can be programmed into automated manufacturing systems. By defining precise parameter values for connector positions and conductor arrangements, the invention enables automated processes to achieve high manufacturing precision through controlled parameter application rather than manual adjustment.
Data Source
AI summary
A stator (1) for an electric machine (101), whereinthe stator (1) has N≥3 phases (U, V, W), P≥2 pole pairs, and q≥1 holes,the stator (1) comprises a stator core (3) having at least 2NPq slots (4) and a number of 2NPqL shaped conductors (5) arranged in an even number of L≥4 layers (6a-h) radially layered in the slots (4),the shaped conductors (5) form 2q paths (7a-d) per phase and are arranged in 2P winding zones (8), which each extend radially over L layers (6a-h) and in the circumferential direction over at least q directly adjacent slots (4),the shaped conductors (5) of each path are connected in a series circuit, which is provided by connectors (9a-e, 10a-f, 11a-g) arranged at both end faces (2a, 2b) of the stator core,each path comprises L/2 groups (12a-d) of shaped conductors (5) successively connected in series,each group (12a-d) is formed by at least one arrangement (13a, 13b) of at least four shaped conductors (5) which are arranged alternately in two immediately adjacent layers (6a-g) and are connected in series by first connectors (9a-e) which each provide an offset by qN slots (4) and an offset by one layer, andpairs of groups (12a-d) adjacent with respect to the series connection are each connected by a second connector (10a-f) which provides an offset by a plurality of slots (4) and an offset by two layers.