Electric Machine Winding Assembly Circumferential Alignment
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Solution Overview
Problem
Existing electric machine winding assemblies in electrified vehicles face challenges with increased power outputs and thermal management due to larger packaging requirements, where radial alignment of conductor ends leads to larger winding diameters and poor insulation, increasing complexity and assembly time.
Innovation Solution
The electric machine winding assembly features a stator with windings arranged in a circumferential alignment, allowing for a reduced winding diameter, sufficient insulation gaps, and clamp gaps to facilitate efficient insulation layer insertion and compression, utilizing bends to orient conductor ends for efficient welding and reduced packaging space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conductor ends are radially aligned to facilitate welding, then welding is simplified, but winding diameter increases and insulation quality deteriorates
Solution Approach 1:
The patent transitions from radial alignment (one-dimensional arrangement along the radius) to circumferential alignment (one-dimensional arrangement along the circumference), and enables two-dimensional spacing by positioning conductor ends at different circumferential locations. This dimensional change allows both welding accessibility and insulation gap requirements to be satisfied simultaneously.
2Manufacturing precision
If windings are arranged with larger diameter to accommodate insulation, then insulation quality improves, but packaging space increases and power output density decreases
Solution Approach 1:
The patent utilizes the circumferential dimension to position conductor ends and windings, rather than only the radial dimension. By arranging conductor ends at different circumferential locations around the stator, sufficient insulation gaps are created without increasing the radial winding diameter, thus maintaining compact packaging while ensuring insulation quality.
3Volume of moving object
If conductor ends are oriented for circumferential alignment to reduce winding diameter, then packaging space is reduced, but welding alignment becomes more difficult
Solution Approach 1:
The patent incorporates pre-formed bends in the conductor ends during winding fabrication, which preliminarily position the conductor ends in the required circumferential alignment. This preliminary action eliminates the need for complex alignment operations during assembly, as the conductor ends are already oriented correctly for welding when the winding is installed on the stator.
4Manufacturing precision
If multiple insulation layers are added to improve insulation, then insulation quality improves, but assembly complexity and time increase
Solution Approach 1:
The patent integrates insulation layers into the winding structure during the winding fabrication process itself, rather than adding them separately during assembly. The insulation layers are positioned and secured preliminarily, so that when the winding is installed on the stator, the insulation is already in place, eliminating additional insulation installation steps and reducing assembly complexity.
Data Source
AI summary
An electric machine winding assembly including a stator and windings is provided. The stator may define a central axis. The windings may extend from the stator and each may include a pair of conductor ends. Each conductor end may include a minor side and a major side. The windings are arranged with the stator such that each of the major sides are aligned along a circumferential conductor axis relative to the central axis to facilitate welding adjacent conductor ends to one another. Each of the windings may further include two portions defining a U shape. Each of the two portions may include a lower portion, a mid-portion, and an upper portion. One of the mid-portions may include a first bend defining a twist shape to orient the major sides of one of the pair of conductor ends along the circumferential conductor axis.