Stator Winding Segmentation for Rotary Machine Slot Insertion

Solution Overview

Problem

Existing stator winding configurations for rotary electric machines, such as concentric and lap wound coils, face inefficiencies in winding usage and complexity in inserting coils into slots, leading to wasteful portions and difficulty in mechanization.

Innovation Solution

A stator winding configuration using a single layer lap wound coil with divided unit coils and a specialized jig system for inserting coils into slots, reducing wasteful usage and facilitating easier insertion by employing a coil retaining jig to prevent coils from being dislodged.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a concentric wound coil is used, then the arrangement is simple, but the amount of wasteful portions increases

Engineering Contradiction:

Improvearrangement simplicityVSAvoidwasteful portions

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The coil is divided into multiple segments (first coil and second coil) with different winding directions. The first coil winds in one direction while the second coil winds in the opposite direction, allowing the end portions to be positioned and utilized more effectively, thereby reducing waste while maintaining manufacturing simplicity.

Inventive Principle:

Principle #1Segmentation

2Loss of substance

If a lap wound coil is used, then the amount of wasteful portions decreases, but the arrangement complexity increases

Engineering Contradiction:

Improvewasteful portionsVSAvoidarrangement complexity

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The coil is divided into multiple segments (first coil and second coil) with different winding directions. The first coil winds in one direction while the second coil winds in the opposite direction, allowing the end portions to be positioned and utilized more effectively, thereby reducing waste while maintaining manufacturing simplicity.

Inventive Principle:

Principle #1Segmentation

3Productivity

If a lap wound coil is used, then the winding efficiency improves, but the insertion difficulty increases

Engineering Contradiction:

Improvewinding efficiencyVSAvoidinsertion difficulty

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The coil is divided into multiple segments (first coil and second coil) with different winding directions. The first coil winds in one direction while the second coil winds in the opposite direction, allowing the end portions to be positioned and utilized more effectively, thereby reducing waste while maintaining manufacturing simplicity.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS9698643B2Stator winding for rotary electric machine, stator for rotary electric machine, method of manufacturing stator for rotary electric machine, and jig used in manufacturing stator for rotary electric machine

Publication Date: 2017.07.04 TOSHIBA IND PROD & SERVICES CORP

AI summary

A stator winding of a rotary electric machine includes windings for each pole of each phase being configured by a single layer lap wound coil. The single layer lap-wound coil includes combination coils each configured by two or more divided unit coils of the same phase being disposed one over the other in a radial direction inside slots of a stator core. The combination coils each comprise a first-row unit coil and a second-row unit coil disposed in a radially inner side of the stator core with respect to the first-row unit coil. A turns count of the first-row unit coil equals a turns count of the second-row unit coil. A count of lead wires of the first-row unit coil differs from a count of lead wires of the second-row unit coil.