Stator Windings with Radial Tilt for Compact Generator Design
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Solution Overview
Problem
In large electrical machines with a high number of poles and small pole pitch, traditional double-layer windings are difficult to mount due to the need to temporarily lift coils, and single-layer windings result in large copper-consuming winding overhangs.
Innovation Solution
A group of three stator windings with pre-formed closed loops, where each winding has two parallel segments embedded in adjacent slots, and winding heads that differ in tilt to minimize copper usage and reduce overall length, allowing for a compact and efficient stator arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If single-layer windings are used to avoid coil removal during assembly, then ease of manufacture is improved, but winding overhangs increase leading to larger copper consumption
Solution Approach 1:
The patent applies local quality by differentiating the winding head segments of different phases. Specifically, the winding head segments are tilted at different angles relative to the axial direction, with each phase having a distinct tilt angle. This localized variation in geometry allows the winding heads to be compactly arranged without requiring excessive copper, while maintaining the ease of single-layer assembly.
2Ease of manufacture
If traditional double-layer windings are used, then all coils are identical and easy to manufacture, but mounting becomes difficult requiring temporary coil removal
Solution Approach 1:
The patent inverts the traditional double-layer winding approach by using single-layer windings with differentiated winding heads. Instead of making all coils identical as in double-layer windings, the invention makes the winding heads different while keeping the coil structure simple and the assembly process straightforward. This inversion resolves the assembly complexity issue while maintaining manufacturing ease through a different design philosophy.
3Loss of substance
If winding heads are made compact to reduce copper usage, then copper consumption decreases, but the axial dimension of the stator increases
Solution Approach 1:
The patent applies dimensionality change by tilting the winding head segments in the radial direction rather than extending them axially. Instead of reducing copper usage at the expense of axial length, the invention redistributes the winding head volume into the radial dimension through tilting. This allows compact axial dimensions while maintaining reduced copper consumption through optimized winding head geometry.
Data Source
AI summary
A group of three stator windings for a stator of an electric machine, a stator arrangement, a generator, and wind turbine are provided. The first winding head segments of the three stator windings differ in form such that the first winding head segments of at least two of the three stator windings are differently tilted in radial direction of the electric machine and the length of the three stator windings is substantially the same.