Two-Layer Strip Winding Layout for Easier Stator Slot Insertion
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Solution Overview
Problem
Existing strip-like winding units for electrical machines are often very long and have multiple layers, leading to high manufacturing costs and increased difficulty in processing and insertion into stator cores.
Innovation Solution
A stator with a strip-like winding unit featuring two layers of winding conductors, where bent end sections connect slot sections across layers, allowing for a spiral arrangement that reduces thickness to two layers, facilitating easier insertion and reducing manufacturing effort by allowing slot sections to occupy different radial positions in the stator core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If strip-like winding units are made very long to extend several times around the stator circumference, then the winding can cover more area, but the manufacturing cost increases significantly
Solution Approach 1:
The winding unit is divided into a modular structure with multiple slot sections arranged in parallel, connected by bent end sections. This segmentation allows the winding to achieve extended coverage through modular repetition rather than creating one extremely long continuous winding, thereby reducing manufacturing complexity and cost while maintaining the required winding area coverage.
2Quantity of substance
If strip-like winding units have a large number of layers, then the winding can accommodate more conductors, but the difficulty of processing and insertion into the stator core increases
Solution Approach 1:
Instead of increasing the number of layers in the vertical dimension, the invention arranges multiple slot sections in parallel along the transverse direction, effectively distributing conductors across the horizontal dimension. The bent end sections connect these parallel slot sections, allowing multiple conductors to be accommodated without stacking them in multiple layers, thus reducing insertion difficulty while maintaining the required number of conductors.
Data Source
AI summary
A stator for an electric machine, comprising a stator core and a stator winding, wherein the stator core has a plurality of slots, which are spaced apart in a circumferential direction and have a depth running in the radial direction, and allows the arrangement of slot sections of the stator winding in a plurality of radially spaced-apart radial positions, wherein the stator has a strip-like winding unit comprising a first and a second winding conductor, wherein the two winding conductors run in a first and a second layer of the winding unit and each comprises:a plurality of straight slot sections which run in a transverse direction of the winding unit and are arranged in parallel,a plurality of first bent end sections which each interconnect two slot sections of the associated winding conductor and are arranged on a first longitudinal side of the winding unit,a plurality of second bent end sections which each interconnect two slot sections of the associated winding conductor and are arranged on a second longitudinal side of the winding unit, which second longitudinal side is situated opposite the first longitudinal side, wherein,the first and the second bent end sections each interconnect a slot section of the associated winding conductor in the first layer and a slot section of the associated winding conductor in the second layer,wherein a first slot section is arranged in a first slot in a first radial position, and a second slot section, which is directly connected to the first slot section by a first end section, is arranged in a second slot in a second radial position which is offset by two radial positions in relation to the first radial position.