Stator winding having transitions

• US 20050046297A1
• Filed: 08/09/2004
• Published: 03/03/2005
• Est. Priority Date: 01/24/2002
• Status: Active Grant

• Current Assignee: Remy Technologies LLC (BorgWarner Incorporated)
• Original Assignee: Visteon Global Technologies Incorporated (Visteon Corporation)
• Inventors: Neet, Kirk E., Chen, Hanyang Ben
• Granted Patent: US 7,170,211 B2
• Time in Patent Office: Days
• US Class Current: 310/180
• CPC Class Codes: H02K 15/0037 Shaping or compacting winding heads H02K15/005, H02K15/0087 and H02K15/0428 take precedence
• CPC Class Codes: H02K 3/12 arranged in slots
• CPC Class Codes: H02K 3/28 Layout of windings or of connections between windings windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32
• CPC Class Codes: H02K 3/50 Fastening of winding heads, equalising connectors, or connections thereto

Abstract

A stator for an electric machine includes a generally cylindrically-shaped stator core having a plurality of circumferentially spaced core slots. A stator winding includes a plurality of phases, each including at least a first filar and a second filar extending circumferentially around the stator core to form a plurality of layers. Each of the filars is a conductor having a plurality of slot segments disposed in the core slots. The slot segments are alternately connected at the first and second ends of the stator core by a plurality of end loop segments that may form a cascaded winding pattern. The plurality of filars of each phase alternating radial positions with one another within at least one end loop segment at discreet locations around the stator core such that the average radial position of the slot segments of the first filar conductors is substantially equal to that of the second filar.

Claims

1. A stator for an electric machine, comprising:

a generally cylindrically-shaped stator core having a plurality of circumferentially spaced and axially-extending core slots in a surface thereof, said core slots extending between a first and a second end of said stator core;

a stator winding having a plurality of phases, each phase comprising at least a first filar and a second filar extending circumferentially around said stator core to form a plurality of layers;

each of said filars being a conductor having a plurality of slot segments disposed in said core slots, said slot segments alternately connected at said first and second ends of said stator core by a plurality of end loop segments,

said first filar having a first set of a plurality of consecutive slot segments having at least a first and second consecutive slot segment wherein each slot segment is disposed at substantially the same radial distance from a central axis of said stator core and having a second set of a plurality of consecutive slot segments having at least a third and fourth consecutive slot segment wherein each slot segment is disposed at substantially the same radial distance from a central axis of said stator core;

said plurality of consecutive slot segments of said first set being disposed at substantially the same radial distance from a central axis of said stator core as said plurality of consecutive slot segments of said second set; and

said slot segments of said first and second filars of a particular phase alternating radial positions with one another within at least one discreet location around said stator core.

2. The stator of claim 1 wherein said first and second filars of a particular phase alternate radial positions with one another within at least one discreet location and said first filar forms transitions within end loop segments located at only one end of said stator core.

3. The stator of claim 2 wherein said first and second filars of a particular phase alternate radial positions with one another and said first filar forms transitions within every end loop segment at only one end of said stator core.

4. The stator of claim 2 wherein said first and second filars of a particular phase alternate radial positions with one another within said end loop segments at only two discreet locations.

5. The stator core of claim 4 wherein said two discreet locations are located substantially 180 degrees apart from one another.

6. The stator of claim 1 wherein said first and second filars of a particular phase alternate radial positions with one another within at least two discreet locations, and said first filar forms transitions at least once at each end of said stator core.

7. The stator of claim 6 wherein said first and second filars of a particular phase alternate radial positions with one another within said end loop segments at only two discreet locations, and said first filar forms transitions at a first discreet location at said first end of said stator core and at a second discreet location at said second end of said stator core.

8. The stator of claim 1 wherein said first filar and said second filar of each phase each include a first end and a second end, said first ends of said first and second filars being connected to one another and said second ends of said first and second filars being connected to one another such that said first and second filars are connected in parallel.

9. The stator of claim 8 wherein said first ends of said filars of a first half of said phases are connected to a first neutral point and said second ends of said filars of said first half of said phases are connected to a rectifier, and said first ends of said filars of a second half of said phases are connected to a second neutral point and said second ends of said filars of said second half of said phases are connected to a rectifier.

10. The stator according to claim 1 wherein said end loop segments of each particular layer include a first sloped portion substantially co-radial with said slot segments of said particular layer and a second sloped portion substantially non-co-radial with said slot segments of said particular layer, said first and second sloped portions connected by an apex portion thereof.

11. The stator according to claim 1 wherein at least one of said end loop segments of the portion of the conductors including a series of consecutive slot segments located at the same radial distance form the central axis includes two radial adjustments to form a cascaded winding pattern.

12. The stator according to claim 1 including at least three layers and wherein at least one of said layers is shifted a predetermined number of slots from at least one of another of said layers.

13. The stator according to claim 12 wherein said end loop segments of a one of said layers extend radially outwardly in a counterclockwise direction on said first end of said stator core and said end loop segments of another one of said layers extend radially outwardly in a clockwise direction on said first end of said stator core.

14. A stator for an electric machine, comprising:

a generally cylindrically-shaped stator core having a plurality of circumferentially spaced and axially-extending core slots in a surface thereof, said core slots extending between a first and a second end of said stator core; and

a stator winding having a plurality of phases, each phase comprising at least a first filar extending circumferentially around said stator core to form a plurality of layers;

said first filar being a conductor having a plurality of slot segments disposed in said core slots, said slot segments alternately connected at said first and second ends of said stator core by a plurality of end loop segments;

a plurality of consecutive slot segments of said first filar of a particular one of said phases being disposed substantially in the innermost layer and another plurality of consecutive slot segments of said first filar being disposed substantially in a different layer;

at least one end loop segment connecting said plurality of consecutive slot segments disposed in said innermost layer having a portion of the end loop segment which is at a different radial distance from the central axis of said stator core as any portion of said slot segments disposed in said innermost layer; and

at least one end loop segment connecting said plurality of consecutive slot segments disposed in said different layer having a portion of the end loop segment which is at a different radial distance from the central axis of said stator core as any portion of said slot segments disposed in said different layer.

15. The stator according to claim 14 wherein the number of said consecutive slot segments of said first filar which are disposed in said innermost layer is at least three and wherein the number of said consecutive slot segments of said first filar which are disposed in said different layer is at least three.

16. The stator according to claim 14 wherein said consecutive slot segments of said first filar which are disposed in said different layer are disposed in the second innermost layer.

17. The stator according to claim 15 wherein a portion of said first filar including said plurality of consecutive slot segments being disposed in the innermost layer is formed from a single continuous conductor and a portion of said first filar including said consecutive slot segments being disposed in said different layer is formed from a single continuous conductor.

18. The stator according to claim 17 wherein said portion of said first filar including said plurality of consecutive slot segments being disposed in the innermost layer and said portion of said first filar including said plurality of consecutive slot segments being disposed in said different layer are formed from the same single continuous conductor.

19. The stator according to claim 14 wherein a plurality of said end loop segments connect said slot segments disposed in a particular slot with a slot segment disposed in a slot which is located six slots from said particular slot.

20. The stator of claim 14 wherein said phases each include at least three filars and said filars of each phase each include a first end and a second end, said first ends of said filars being connected to one another and said second ends of said filars being connected to one another such that said filars are connected in parallel.

21. A stator for an electric machine, comprising:

a generally cylindrically-shaped stator core having a plurality of circumferentially spaced and axially-extending core slots in a surface thereof, said core slots extending between a first and a second end of said stator core;

a stator winding having a wave winding configuration and having a plurality of phases, each phase comprising at least a first filar extending circumferentially around said stator core to form a plurality of layers;

said first filar being a conductor having a plurality of slot segments disposed in said core slots, said slot segments alternately connected at said first and second ends of said stator core by a plurality of end loop segments;

said first filar of a particular one of said phases having at least three consecutive slot segments being disposed in a particular layer and at least three consecutive slot segments being disposed in a different particular layer;

a portion of said first filar including all of said at least three consecutive slot segments being disposed in said particular layer being formed from a single continuous conductor;

a portion of said first filar including all of said at least three consecutive slot segments being disposed in said different particular layer being formed from a single continuous conductor;

a plurality of end loop segments connecting a first slot segment disposed in a first particular core slot with a second slot segment disposed in a second particular core slot, wherein each end loop segment is a same layer end loop segment;

each particular one of said same layer end loop segments connecting said first slot segment disposed in said first particular core slot with said second slot segment disposed in said second particular core slot, includes a portion which is located at a different radial distance from the central axis of said stator core as any portion of said slot segments which are connected to said particular one of said same layer end loop segment.

22. The stator according to claim 21 wherein said second particular core slot is located six slots from said first particular core slot.

23. A stator for an electric machine, comprising:

a generally cylindrically-shaped stator core having a plurality of circumferentially spaced and axially-extending core slots in a surface thereof, said core slots extending between a first and a second end of said stator core;

a stator winding having a wave winding configuration and having a plurality of phases, each phase comprising at least a first filar extending circumferentially around said stator core to form a plurality of layers;

said first filar being a conductor having a plurality of slot segments disposed in said core slots, said slot segments alternately connected at said first and second ends of said stator core by a plurality of end loop segments,

said first filar of a particular one of said phases having a first set of a plurality of consecutive slot segments wherein each slot segment is disposed at substantially the same radial distance from a central axis of said stator core, having a second set of a plurality of consecutive slot segments wherein each slot segment is disposed at substantially the same radial distance from a central axis of said stator core, and having a third set of a plurality consecutive slot segments wherein each slot segment is disposed at substantially the same radial distance from a central axis of said stator core;

said plurality of consecutive slot segments of said first set being disposed at substantially the same radial distance from a central axis of said stator core as said plurality of consecutive slot segments of said third set;

said plurality of consecutive slot segments of said second set being disposed at substantially a different radial distance from a central axis of said stator core as said plurality of consecutive slot segments of said first set; and

said second set being located in between said first set and said third set.

24. A stator for an electric machine, comprising:

a generally cylindrically-shaped stator core having a plurality of circumferentially spaced and axially-extending core slots in a surface thereof, said core slots extending between a first and a second end of said stator core;

a stator winding having a plurality of phases, each phase comprising at least a first filar extending circumferentially around said stator core to form a plurality of layers;

said first filar being a conductor having a plurality of slot segments disposed in said core slots, said slot segments alternately connected at said first and second ends of said stator core by a plurality of end loop segments;

said first filar of a particular one of said phases having a plurality of consecutive slot segments being disposed in a particular layer and a plurality of consecutive slot segments being disposed in a different particular layer;

a plurality of end loop segments connecting a first slot segment disposed in a first particular core slot with a second slot segment disposed in a second particular core slot, wherein each end loop segment is a same layer end loop segment;

a particular one of said same layer end loop segment connecting said first slot segment disposed in said first particular core slot with said second slot segment disposed in said second particular core slot, includes a portion which is located at a different radial distance from the central axis of said stator core as any portion of said first and said second slot segments; and

at least one of said same layer end loop segment connecting said first slot segment disposed in said first particular core slot with said second slot segment disposed in said second particular core slot, is located on a first end of the stator core and at least one of said same layer end loop segment connecting said first slot segment disposed in said first particular core slot with said second slot segment disposed in said second particular core slot, is located on a second end of the stator core.

25. The stator according to claim 24 wherein said slot segments are aligned in one radial row in at least one core slot.

26. The stator according to claim 24 wherein at least half of said same layer end loop segments connecting said first slot segment disposed in said first particular core slot with said second slot segment disposed in said second particular core slot, include a portion which is located at a different radial distance from the central axis of said stator core as any portion of said first and said second slot segments.

27. The stator according to claim 24 wherein said plurality of same layer end loop segments connected to said first slot segment and said second slot segment and a plurality of end loop segments connected to a slot segment disposed in a core slot located in between said first particular core slot and said second particular core slot, form a cascaded winding pattern.

28. A stator for an electric machine, comprising:

a generally cylindrically-shaped stator core having a plurality of circumferentially spaced and axially-extending core slots in a surface thereof, said core slots extending between a first and a second end of said stator core;

a stator winding having a plurality of phases, each phase comprising at least a first filar extending circumferentially around said stator core to form a plurality of layers;

said first filar being a conductor having a plurality of slot segments disposed in said core slots, said slot segments alternately connected at said first and second ends of said stator core by a plurality of end loop segments;

said first filar of a particular one of said phases having a plurality of consecutive slot segments being disposed in a particular layer and a plurality of consecutive slot segments being disposed in a different particular layer;

a plurality of end loop segments connecting a first slot segment disposed in a first particular core slot with a second slot segment disposed in a second particular core slot, wherein each end loop segment is a same layer end loop segment; and

at least one of said same layer end loop segment connecting said first slot segment disposed in said first particular core slot with said second slot segment disposed in said second particular core slot, includes at least one sloped portion.

29. The stator according to claim 28 wherein a particular one of said same layer end loop segment connecting said first slot segment disposed in said first particular core slot with said second slot segment disposed in said second particular core slot, includes a portion which is located at a different radial distance from the central axis of said stator core as any portion of said first and said second slot segments.

30. The stator according to claim 28 wherein at least one of said same layer end loop segment connecting said first slot segment disposed in said first particular core slot with said second slot segment disposed in said second particular core slot, is located on a first end of the stator core and at least one of said same layer end loop segment connecting said first slot segment disposed in said first particular core slot with said second slot segment disposed in said second particular core slot, is located on a second end of the stator core.

31. The stator according to claim 28 wherein said slot segments are aligned in one radial row in at least one slot.

32. The stator according to claim 28 wherein said plurality of end loop segments connected to said first slot segment and said second slot segment and a plurality of end loop segments connected to a slot segment disposed in a core slot located in between said first particular core slot and said second particular core slot, form a cascaded winding pattern.