Wave-Wound Stator Conductor Layout for Shorter Axial Motors
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Solution Overview
Problem
Conventional wave-wound stators in electric vehicle motors face challenges in securing a long routing path for conductors, leading to increased axial dimensions due to non-circular segment coils and complex folded portions.
Innovation Solution
The motor design incorporates a stator with a rotor that includes a stator core with slots arranged circumferentially, and conductor connection bodies that are wave-wound in a specific configuration with folded portions to connect different portions of the winding, allowing for a more compact and efficient stator structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If wave winding of conventional structure is performed, then routing path of conductor cannot be lengthened, but axial dimension of stator increases when folded portion is provided
Solution Approach 1:
The conductor connection body utilizes the radial dimension of the stator by extending conductors from the inner peripheral surface toward the rotor, rather than only using the axial dimension. This allows the routing path to be lengthened in the radial direction, avoiding the need for long axial extensions. The conductor is routed through the radial space between the stator core and rotor, effectively using unused dimensional space to resolve the contradiction between routing path length and axial dimension.
2Length of stationary object
If segment coil is made non-circular to accommodate folded portion, then routing path can be extended, but flexibility of conductor decreases and axial dimension increases
Solution Approach 1:
Instead of deforming the conductor in the axial direction which reduces flexibility, the invention routes the conductor in the radial direction. The conductor maintains its natural flexibility by bending in the radial plane rather than being forced into complex axial configurations. This dimensional change allows the routing path to be extended without compromising conductor flexibility or requiring non-circular segment coil designs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design effectively reduces the axial dimension of the stator while maintaining efficient conductor routing, thereby enhancing the motor's compactness and performance.
Implementation Method 1
A motor includes a rotor that is rotatable about a central axis and a stator that is arranged radially outward of the rotor. The stator includes a stator core having a plurality of slots arranged in a circumferential direction and a plurality of conductor connection bodies which have a plurality of conductors connected in series and are inserted into the plurality of slots.
Data Source
AI summary
In a motor, a stator includes: a stator core having slots arranged in a circumferential direction; and conductor connection bodies with conductors connected in series and inserted into the slots. A conductor connection body includes: a first portion wave-wound toward one side in the circumferential direction from a first end to a second end; a second portion wave-wound toward the one side in the circumferential direction from a third end to a fourth end; and a folded portion connecting the first and second portions. The first and third ends protrude in an axial direction from different slots in the circumferential direction, and the second and fourth ends protrude in the axial direction from different slots in the circumferential direction. The conductors include a folded conductor that forms a folded portion connecting the second end of the first portion and the fourth end of the second portion.