Stator Winding Elements with Reversal Sections for Cooling
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Solution Overview
Problem
Existing stator windings for electrical machines, particularly in multi-phase motor-vehicle generators with claw-pole rotors, face challenges with disordered wire paths leading to inefficient cooling and increased manufacturing complexity due to high numbers of interconnection points, which prolong manufacturing time and increase costs.
Innovation Solution
The use of winding elements with multiple sections and reversal sections inserted in slots, allowing for improved radial positioning and reduced interconnection points, enabling better airflow through the winding overhangs and simplified assembly, while maintaining effective cooling and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If disordered wire paths are used in winding overhangs, then the winding assembly is simple, but cooling efficiency deteriorates and winding dimensions increase
Solution Approach 1:
The winding overhang is segmented into multiple individual conductor sections instead of a disordered mass. Each conductor is separated and positioned individually, creating a structured arrangement that allows cooling air to flow through the winding overhang while maintaining manufacturing simplicity through modular assembly.
2Length of moving object
If insert/twist technique with U-shaped conductor sections is used, then overall generator length and weight are reduced, but the number of interconnection points increases manufacturing complexity
Solution Approach 1:
Multiple conductor sections are merged into a single pre-assembled winding element before insertion into the stator slot. This reduces the number of separate insertion operations and interconnection points during final assembly, while maintaining the compact structure benefits of the insert technique.
Solution Approach 2:
The winding element is pre-assembled with conductors positioned and connected before insertion into the stator. This preliminary preparation reduces the complexity of on-site assembly operations and minimizes the number of interconnection points that need to be created during final installation.
3Manufacturing precision
If many interconnection points are required for winding assembly, then manufacturing precision can be maintained, but manufacturing time and costs increase
Solution Approach 1:
The winding assembly process is segmented into pre-manufacturing of winding elements and final insertion into the stator. This allows precision work to be done on individual elements in a controlled setting, while final assembly is simplified to insertion operations, reducing overall manufacturing time without sacrificing precision.
Solution Approach 2:
The winding element is designed to be self-positioning and self-aligning during insertion into the stator slot. The structure of the winding element includes features that automatically ensure correct positioning, reducing the need for complex alignment procedures and multiple interconnection points during assembly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces the number of interconnection points, improves cooling efficiency by allowing airflow through the winding overhangs, and simplifies the assembly process, leading to cost savings and reduced manufacturing time while maintaining high insulation quality.
Implementation Method 1
winding overhangs (45, 46) that in each case are able to be cooled by an approximately radial air flow produced by at least one fan (30) mounted at the rotor
Data Source
AI summary
An alternating-current generator, in particular a three-phase generator, for a motor vehicle, having a rotor including north and south poles, particularly having claw-pole fingers extending in the axial direction and alternating as north and south poles at the rotor's periphery, a stator having a magnetic core, especially laminated core, having slots and a stator winding disposed in the magnetic core's slots, the stator winding having winding overhangs that are coolable by an approximately radial air flow produced by at least one fan mounted at the rotor, the stator being situated opposite the rotor, and the stator and the rotor having defined positions relative to each other, the multiphase stator winding being made up of winding elements, at least one winding element having more than two sections inserted in slots, and at least one winding element having more than one reversal section which brings about a change in the radial position.