Stator Winding Method Using U-Shaped Conductors

Solution Overview

Problem

Existing motor stator winding methods face challenges such as high production costs, complex manufacturing processes, and a high risk of voltage-induced insulation breakdown due to voltage differences between stator winding layers, leading to motor failures.

Innovation Solution

A coil winding method for a stator module that uses U-shaped conductor sections with specific configurations and welding techniques to reduce voltage differences between layers, simplify the manufacturing process, and enhance electrical reliability, involving steps like spanning stator slots in alternating directions to minimize voltage disparities and reduce the number of welding points.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional wave winding mode is used, then the stator windings can be connected, but the manufacturing process becomes complex and production cost increases

Engineering Contradiction:

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent divides the traditional complex winding process into simplified modular steps. The stator windings are segmented into discrete units that can be independently positioned and connected, reducing the overall complexity of the winding process while maintaining electrical connectivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs preliminary positioning of flat wires in the stator slots before final winding. By pre-arranging the conductor positions and preparing the winding structure in advance, the actual winding process is simplified, reducing manufacturing complexity and cost.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If flat wire armatures with multiple welding spots are used, then electrical connection is achieved, but production cost increases

Engineering Contradiction:

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges multiple welding spots into fewer connection points by redesigning the winding structure. Adjacent windings are combined to share common connection points, reducing the total number of welding operations required while maintaining reliable electrical connections across all stator phases.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent creates universal connection structures that serve multiple functions. The same welding structure is used across different phases and windings, allowing a single design to handle multiple electrical connection requirements, thereby reducing overall production cost and improving manufacturing efficiency.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Power

If high voltage difference between stator winding layers is present, then electrical connection is established, but insulation breakdown risk increases

Engineering Contradiction:

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The patent arranges flat wires in alternating layers to create equipotential regions. By positioning conductors with similar electrical potentials adjacent to each other in the same slot layers, voltage differences between adjacent insulation layers are minimized, reducing the risk of insulation breakdown while maintaining power transmission capability.

Inventive Principle:

Principle #12Equipotentiality

Solution Approach 2:

The patent applies different insulation strategies to different regions of the stator windings. High-voltage stress regions receive enhanced insulation treatment, while low-stress regions use standard insulation, optimizing the overall insulation system to prevent breakdown without excessive material usage.

Inventive Principle:

Principle #3Local quality

4Reliability

If complex winding configurations are used, then electrical performance is improved, but manufacturing difficulty increases

Engineering Contradiction:

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent designs the winding structure to be self-aligning and self-positioning. The flat wires and conductor sections are configured to automatically assume their correct positions during assembly without requiring complex external positioning mechanisms, thereby improving manufacturing ease while maintaining reliable electrical connections.

Inventive Principle:

Principle #25Self-service

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

The method reduces the risk of motor insulation breakdown, simplifies the manufacturing process, and lowers production costs by minimizing voltage differences between stator layers, thereby improving the reliability and efficiency of the motor stator winding.

Implementation Method 1

welding and connecting the first in-slot portion and the second in-slot portion in different layers of the multiple U-shaped conductor sections to the welding end

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS11323000B2Motor, stator module and coil winding method thereof

Publication Date: 2022.05.03

AI summary

A winding method for a stator module applicable to a motor having z slots, 2p poles, and m phases. The stator module includes a stator core and a winding coil. The winding coil is made of a flat wire. The winding method includes: forwardly winding some stator slots by means of the arrangement and connection of multiple U-shaped conductor sections, and then reversely winding the stator slots; afterwards, forwardly winding the remaining stator slots, and then reversely winding the stator slots; and cycling in this way.