Wave Winding Mat Layout to Prevent Stator Circulating Currents
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Solution Overview
Problem
Existing dynamo electric machines with wave windings face challenges in producing a stator with a continuous winding scheme that is easy to manufacture and effectively prevents circulating currents.
Innovation Solution
The stator design includes axially oriented stator grooves with distributed winding mats containing continuous wave winding conductors, where each conductor occupies different radial positions within the grooves, and the sequence of groove sections is interchanged to prevent circulating currents, with the stator body formed as a toothed chain that can be easily fitted with a winding mat in an unwound state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If wave winding conductors are used with smaller conductor height, then the number of conductors in the groove increases, but circulating currents are generated and manufacturing complexity increases
Solution Approach 1:
The patent applies local quality by creating two distinct radial layers within the stator grooves, where conductors in the first radial layer have a first sequence and conductors in the second radial layer have a second (reversed) sequence. This local differentiation in arrangement prevents circulating currents while accommodating the increased number of conductors resulting from smaller conductor height.
Solution Approach 2:
The patent segments the conductors into two separate radial layers within each stator groove. This segmentation allows independent sequencing of conductors in each layer, enabling the reversal of sequence in the second layer to eliminate circulating currents while maintaining the higher conductor count.
2Ease of manufacture
If stator is formed as bent toothed chain, then ease of manufacture improves, but structural complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-assembling the winding mat in its complete, functional configuration within the bent toothed chain stator before final assembly. The winding mat is prepared with all conductors properly positioned in their respective radial layers and sequences, allowing straightforward integration into the stator without complex post-assembly adjustments.
Solution Approach 2:
The patent merges the winding mat assembly with the bent toothed chain stator structure, integrating the distributed winding directly into the pre-formed stator body. This combination simplifies the overall manufacturing process by eliminating separate winding and stator assembly steps.
3Stability of the object's composition
If groove sections are distributed over q adjacent stator grooves, then winding continuity improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies parameter changes by systematically varying the radial layer assignment and sequence ordering of conductors across different stator grooves. This controlled parameter variation maintains winding continuity through proper distribution over q adjacent grooves while providing clear manufacturing guidelines that reduce positioning precision requirements.
Data Source
AI summary
A dynamo electric machine stator which is easy to assemble, includes a stator body with stator grooves and a winding mat with groove sections arranged in the stator grooves and lie one over the other in different radial positions, and with head sections which connect the groove sections. A wave winding conductor changes position by precisely one radial position in the stator grooves in the center of the extension of the wave winding conductor in the winding direction. The winding mat includes a first sub-winding mat with one first set of wave winding conductors for each section, the first sets being joined together in an X-shaped manner in the region of the position change such that the conductors are aligned in a specific manner at the intersections between the wave winding conductors.