Stator Winding Segmentation for Short Circuit Safety
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Solution Overview
Problem
Safety-critical electric motor applications, such as power steering systems, face risks of short circuits due to damage to the insulating lacquer of electrical windings, potentially leading to motor blockage.
Innovation Solution
The stator winding is designed with two electrically separate winding strands, allowing the motor to continue operating even if one strand experiences a short circuit, with each strand wound on opposite stator halves and interconnected using a plastics ring interconnect plate to prevent crossing wires and minimize the likelihood of further short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single continuous winding is used, then the manufacturing process is simple, but the reliability is reduced due to short circuit risks
Solution Approach 1:
The winding is divided into two independent winding strands (first winding strand and second winding strand) that are electrically separate and geometrically separated on opposite stator halves. This segmentation ensures that a short circuit in one strand does not affect the other, thereby improving reliability while maintaining manufacturing simplicity through modular assembly
2Adaptability or versatility
If connecting wires cross between sub-coils, then the interconnection is flexible, but the likelihood of short circuits increases
Solution Approach 1:
The connecting wires are arranged in axially different planes on the insulating lamination, utilizing the axial dimension to separate wire paths. This dimensional arrangement prevents wire crossing and contact while maintaining the flexibility to interconnect sub-coils, thereby reducing short circuit risk without sacrificing interconnection adaptability
3Volume of moving object
If all sub-coils are wound on a single stator, then the winding structure is compact, but the motor cannot operate safely if a short circuit occurs
Solution Approach 1:
The stator is divided into two stator halves with each winding strand assigned to a separate half. This spatial segmentation allows the motor to maintain safe operation by using one functional half even when the other experiences a short circuit, improving reliability while keeping the overall structure compact through integrated design
Solution Approach 2:
The dual independent winding strands provide a backup system that cushions against the harmful effect of short circuits. If one strand fails, the other strand can continue to operate, providing beforehand protection for safety-critical applications
Data Source
AI summary
Disclosed are a stator (10) for an electric machine (12) and a method for manufacturing a stator of said type which comprises a stator body (34) that has radial stator teeth (14); each stator tooth (14) accommodates exactly one coil section (18) of an electric winding (16); the winding (16) consists of exactly two separate winding strands (24, 25) which are wound from exactly two separate winding wires (22) and each of which has three phases (26) comprising at least two coil sections (18, 17) each.