Dual-Layer Wave Winding Mat Layout for Odd Winding Layers
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Solution Overview
Problem
Existing dual-layer wave winding mats for electric motors are limited by the requirement for an even number of winding layers, leading to increased weight and installation space needs, as well as limitations in power and torque requirements.
Innovation Solution
A dual-layer wave winding mat design where the first and second mats are offset in a longitudinal direction, allowing for an odd number of winding layers, with the start and end regions having equal lengths and conductor inputs and outputs arranged oppositely in different layers, forming a single-layer start and end region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If two single-layer wave winding mats are simultaneously integrated to produce dual-layer wave winding mats, then production time is reduced and costs are reduced, but the number of winding layers must always be an even number and combinations are very limited
Solution Approach 1:
The winding mat is segmented into a first mat and a second mat that are offset relative to each other in the longitudinal direction. This segmentation allows the first mat to form a single-layer start region and the second mat to form a single-layer end region, while their webs overlap in pairs between these regions. This enables flexible configuration of winding layers including odd numbers, resolving the limitation of fixed even-numbered layers while maintaining production efficiency.
Solution Approach 2:
The invention introduces a longitudinal direction offset between the first and second mats, creating a new dimensional arrangement. By offsetting the mats along the longitudinal axis rather than simply stacking them, the design enables variable winding layer configurations including odd numbers, thereby expanding design flexibility without compromising the dual-layer production advantage.
2Ease of manufacture
If the number of conductor portions per slot is fixed to an even number, then dual-layer wave winding can be produced, but power requirements and torque requirements must be significantly outperformed leading to higher weight and installation space
Solution Approach 1:
Different regions of the winding mat have different structural qualities: the start region and end region are single-layer regions formed by the first and second mats respectively, while the intermediate regions are dual-layer regions where webs overlap in pairs. This local differentiation allows optimization of conductor portions per slot to match actual power and torque requirements, reducing unnecessary weight while maintaining manufacturability.
3Power
If conductor portions per slot are increased to meet power and torque requirements, then power and torque capabilities are enhanced, but weight and installation space requirements increase
Solution Approach 1:
The first and second mats are merged in the intermediate regions where their webs overlap in pairs, creating efficient dual-layer sections. The start and end regions use single-layer configurations to optimize space. This merging strategy allows precise control of conductor portions per slot to meet power requirements without unnecessarily increasing installation space, as the offset arrangement maximizes space utilization.
Data Source
AI summary
A dual-layer wave winding mat for power-dependent component of an electric machine, formed of a first mat and an identical second mat, each having at least one conductor strand which includes at least one conductor formed in parallel webs and winding heads which connect the latter to one another. The webs of the first mat and the webs of the second mat are arranged to alternate in a first mat plane and a second mat plane. The first mat and the second mat are arranged to be offset relative to one another such that a single-layer start region is formed only by the first mat and a single-layer end region is formed only by the second mat.