Twisted Apex Stator Coils for Compact Rotary Machines
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Solution Overview
Problem
The existing designs of electric rotary machines face challenges in reducing the size of the stator coil while maintaining adequate insulation performance, as the interference between coil segments leads to reduced insulation and increased size due to the need for larger spanning heights or insulating distances.
Innovation Solution
The stator design features a twisted apex portion of the spanning portions, allowing adjacent coil segments to overlap circumferentially, reducing the spanning height and ensuring the required insulation performance by forming an intersecting state within a specific radial range, which suppresses the size of the electric rotary machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the spanning height is reduced by placing sloping portions of adjacent coil segments as close as possible, then the size of the electric rotary machine is reduced, but the insulation performance is reduced due to interference between coil segments
Solution Approach 1:
The patent introduces a new spatial dimension by twisting the apex portion of the spanning section in the circumferential direction. This twisting creates an intersecting arrangement where the spanning sections of adjacent coil segments cross each other in the circumferential direction while maintaining close proximity in the radial direction, thereby achieving both compact size and adequate insulation distance
Solution Approach 2:
The patent divides the spanning section into distinct functional portions: the apex portion which is twisted in the circumferential direction, and the sloping portions which maintain radial proximity. This segmentation allows different parts of the spanning section to serve different functions - the twisted apex provides insulation separation while the sloping portions minimize overall height
2Reliability
If insulating material is used or insulating distance is ensured at the transition portion, then the insulation performance is improved, but the spanning height is increased which increases the size of the electric rotary machine
Solution Approach 1:
Instead of increasing the radial insulating distance or adding insulating material, the patent resolves the insulation problem by utilizing the circumferential dimension. The twisting of the apex portion creates an intersecting configuration where insulation is achieved through circumferential separation rather than radial separation, thereby maintaining compact spanning height
Data Source
AI summary
One embodiment provides a stator of a segmented conductor type electric rotary machine including an annular stator core and coil. On at least one axial end portion of the stator core, the coils are disposed to form a coil end so that plural spanning portions of the coils are arranged continuously in a circumferential direction and so that circumferentially adjacent ones of the spanning portions partially overlap each other as seen in an axial direction. An apex portion of the spanning portion is twisted so that an intersecting state is formed as seen in a radial direction within a range where the spanning portion is exposed as seen in the axial direction.