Wound Stator Parallel-Edge Slots Rectangular Wire Filling
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Solution Overview
Problem
Existing technologies are limited by a slot fill rate of less than 50% in stator slots of rotating electrical machines, which hinders performance improvement.
Innovation Solution
The use of parallel-edged slots combined with rectangular-section wire, particularly with the largest side oriented parallel or perpendicular to the lateral sides of the teeth, allows for enhanced slot filling, reaching up to 60% fill rate by facilitating coil winding around non-parallel tooth shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If round wires are used in stator slots, then manufacturing is simpler and cost is lower, but the filling ratio is limited to around 45% and space is wasted
Solution Approach 1:
The conductor is divided into multiple segments along its length, with each segment having a different transverse cross-sectional shape (e.g., first segment with rectangular cross-section, second segment with trapezoidal cross-section). This segmentation allows the conductor to be inserted into the stator slot in a structured manner while achieving high filling ratios, resolving the contradiction between manufacturing complexity and space utilization.
Solution Approach 2:
Different portions of the conductor have different cross-sectional shapes optimized for their specific positions. The first segment has a rectangular cross-section suitable for the lower part of the slot, while the second segment has a trapezoidal cross-section that fits the upper part of the slot. This local optimization enables complete slot filling without requiring complex manufacturing processes.
2Quantity of substance
If flat copper bars are used, then filling ratio increases, but connection technology becomes more complex and costly
Solution Approach 1:
The conductor is segmented into multiple portions with different cross-sectional shapes. The first segment has a rectangular cross-section that simplifies connection processes, while the second segment has a trapezoidal cross-section that optimizes space utilization. This segmentation resolves the contradiction by providing simple connections at critical points while maintaining high overall filling ratios.
Solution Approach 2:
The conductor functions as a composite structure with different cross-sectional shapes along its length, combining the advantages of round wires (ease of connection) and flat copper bars (high filling ratio). The first segment with rectangular cross-section facilitates simple connections, while the second segment with trapezoidal cross-section achieves high space utilization.
3Quantity of substance
If irregular cross-sectional shapes are used to optimize filling, then space utilization improves, but manufacturing precision requirements increase
Solution Approach 1:
The conductor is divided into segments with regular geometric shapes (rectangular, trapezoidal) rather than complex irregular shapes. Each segment's dimensions and positions are precisely defined, making manufacturing controllable with standard precision tolerances while achieving high filling ratios through the combination of different geometric forms.
Solution Approach 2:
Each segment has a specific cross-sectional shape optimized for its position in the slot. The first segment has a rectangular cross-section with dimensions optimized for the lower slot region, while the second segment has a trapezoidal cross-section optimized for the upper slot region. This localized optimization achieves high filling ratios without requiring excessive manufacturing precision.
4Quantity of substance
If segmented conductors with different cross-sections are used, then slot filling is optimized, but the number of manufacturing steps increases
Solution Approach 1:
The conductor is segmented into portions that can be manufactured separately and then assembled. The first segment with rectangular cross-section and the second segment with trapezoidal cross-section are produced using standard manufacturing processes and then connected, enabling optimized slot filling while maintaining reasonable manufacturing productivity through modular production.
Solution Approach 2:
The different segments of the conductor are prepared in advance with their specific cross-sectional shapes and dimensions. This preliminary preparation allows for optimized slot filling during assembly without requiring complex real-time manufacturing operations, thereby maintaining productivity while achieving high filling ratios.
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 configuration maximizes the stator slot filling, enhancing the performance of rotating electrical machines by increasing the number of turns and reducing eddy currents.
Implementation Method 1
a three-phase stator (10) with three-phase stator windings (20) arranged in a number of slots (30) of the stator (10)
Data Source
Figure 1~2
Figure 3a~3b
Figure 4~6
AI summary
The invention relates mainly to a wound stator (1) of a rotating electrical machine comprising a yoke (3), teeth (2) distributed on an internal periphery of said yoke (3) extending towards the interior of said stator (1) and delimiting two by two notches (5), as well as coils formed around each tooth (2) from a wire (13) having a substantially rectangular cross-section, characterized in that the lateral flanks (21) of the same tooth (2) are inclined relative to each other, so that two lateral flanks (21) of two adjacent teeth (2) turned towards each other corresponding to the edges delimiting a notch (5) are parallel to each other.