Wave Stator Winding Layout to Minimize Partial Discharge

The patent applies the equipotentiality principle by configuring the wave winding such that adjacent winding waves have equal or nearly equal voltages. This is achieved through a symmetric winding arrangement where the winding tool has a first winding means and a second winding means arranged at a distance from each other, with the stator wire wound around both means in a symmetric pattern. The holding means prevent sideways slipping, and the relative displacement and folding create a balanced configuration where adjacent stator wire sections in the same stator slot have equal voltages, eliminating voltage differences that cause partial discharges without requiring additional insulation material, thus maintaining machine efficiency

The patent eliminates the need for increased insulation layer thickness by achieving equipotential conditions through the winding configuration itself. The symmetric arrangement of first and second winding means, combined with holding means that prevent sideways slipping and controlled relative displacement followed by folding, ensures that adjacent winding waves have equal voltages. This structural solution prevents partial discharges at their root cause (voltage differences) rather than adding insulation, thereby maintaining the efficiency of the electric machine while improving reliability

The patent applies preliminary action by pre-configuring the winding tool with first and second winding means and holding means before the winding process begins. The holding means are预先 installed to prevent sideways slipping of the stator wire during winding. The relative displacement between winding means is predetermined, and the folding angle is controlled during the process. This pre-prepared tooling configuration enables the production of precise wave windings in a continuous, simple process without requiring subsequent welding operations or complex assembly steps