Stator Winding with Variable Cross-Sectional Shape
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Solution Overview
Problem
The existing stator designs with thick flat rectangular wires face challenges in achieving a high coil space factor while maintaining a simple construction, as they require complex wire shape changes and increased costs due to the need for varying cross-sectional shapes and areas with each turn of winding.
Innovation Solution
A stator design featuring a concentrated winding coil with first and second conducting wires, where the second wires have a uniform height and a different cross-sectional shape, such as trapezoidal, pentagonal, or triangular, to maintain a constant circumferential width, improving the coil space factor without increasing complexity or cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If thick flat rectangular wires are wound around teeth to form single-layer coils, then the coil space factor is improved, but the clearance between adjacent coils becomes unfavorably small at the inner peripheral side
Solution Approach 1:
The conducting wires are designed with different cross-sectional shapes at different radial positions. Specifically, wires at the inner peripheral side (first conducting wires) have a smaller cross-sectional area than wires at the outer peripheral side (second conducting wires). This local variation in wire dimensions allows the coil space factor to be maximized at each position, while maintaining adequate clearance between adjacent coils throughout the radial direction.
2Shape
If the cross-sectional shape of conducting wires is changed to match the slot shape, then the clearance between adjacent coils is improved, but the construction becomes complicated and cost increases
Solution Approach 1:
The conducting wires are segmented into two distinct groups based on their radial position: first conducting wires at the inner peripheral side with a first cross-sectional shape, and second conducting wires at the outer peripheral side with a second cross-sectional shape. This segmentation allows each group to have optimized dimensions for its specific location, improving clearance without requiring continuous complex shape variations throughout the entire wire length.
3Shape
If the cross-sectional area of conducting wires is reduced toward the top end of the tooth, then the clearance between adjacent coils is improved, but the coil space factor decreases
Solution Approach 1:
The cross-sectional area parameter of the conducting wires is changed according to the radial position. First conducting wires at the inner peripheral side have a smaller cross-sectional area to accommodate the narrower slot width and maintain adequate clearance, while second conducting wires at the outer peripheral side have a larger cross-sectional area to maximize the coil space factor where more space is available. This parameter optimization at different locations simultaneously achieves both objectives.
Data Source
AI summary
A stator for a rotary electric machine has a tooth whose width in a circumferential direction is substantially constant in a radial direction of the stator, and a concentrated winding coil including winding conducting wires around the tooth. A height of a first conducting wire of the sixth turn at a tooth's top end side measured from a surface of the tooth is lower than a height of a conducting wire adjacent to a tooth's root end side of the conducting wire measured from the tooth surface. Conducting wires of the first to fifth turns, that is, second conducting wires, have the same height from the surface of the tooth.