Stator Winding Sheet Multi-Turn Configuration
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Solution Overview
Problem
Existing methods for producing windings for rotating electrical machine stators are inefficient in filling slots and require robust comb structures, which can weaken the comb and complicate the winding process.
Innovation Solution
A method involving a winding sheet wound around the stator body with fewer than two turns, using segment and loop structures that alternate between internal and external layers, and with loop structures connecting segment structures in adjacent slots to optimize slot filling and reduce comb height, allowing for a more rigid and efficient winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a robust comb structure is used to accommodate multiple conductor layers, then the comb can handle the winding process, but the comb walls become weaker due to reduced height requirements
Solution Approach 1:
The patent transitions from a single-layer winding approach to a multi-turn winding sheet approach, where conductors are wound in multiple turns (at least two) around the stator body. This dimensional change in the winding process allows the comb structure to be optimized for rigidity while maintaining the ability to accommodate multiple conductor layers through the multi-turn configuration rather than requiring tall comb walls
2Strength
If the comb wall height is reduced to manipulate thinner winding sheets, then the comb becomes more rigid, but the ability to accommodate different conductor layers is compromised
Solution Approach 1:
The patent implements a continuous winding process where the winding sheet is wound in multiple turns around the stator body, creating a continuous sequence of conductor layers. This continuous multi-turn action allows thin winding sheets to be accumulated into multiple conductor layers, enabling the comb to have reduced wall height while maintaining rigidity, as the multi-turn continuous process naturally builds up the required conductor layers without requiring tall comb walls to accommodate them
3Productivity
If conventional winding methods are used, then the winding process can be completed, but slot filling efficiency is suboptimal
Solution Approach 1:
The patent prepares the winding sheet in advance with pre-formed segment structures and loop structures before the actual winding process. The winding sheet is configured with conductors arranged in specific patterns (segment structures in slots, loop structures connecting them) before being wound around the stator body. This preliminary configuration of the winding sheet enables optimized slot filling during the winding process, as the pre-arranged conductor structures are directly transferred to the stator slots in the correct positions, improving both productivity and manufacturing precision
Data Source
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AI summary
The invention essentially relates to a method for the production of a winding of a rotary electric machine stator, comprising the following steps: forming a winding web (52) comprising a plurality of conductors (37); placing the winding web (52) in a comb (83); winding the winding web (52) around a spindle (105) such as to obtain a winding; and transferring the winding from the spindle (105) to the stator, characterised in that the winding web (52) is wound around the stator (105) over at least two turns.