Distributed cascaded winding for electric machines

Patent metadata

Field	Value
Publication number	US-10110078-B2
Application number	US-201313974591-A
Country	US
Kind code	B2
Filing date	Aug 23, 2013
Priority date	Aug 23, 2013
Publication date	Oct 23, 2018
Grant date	Oct 23, 2018

Abstract

A stator includes a cylindrical core with a plurality of longitudinally extending slots, a first winding set formed as a first cascaded wire in two radial layers of the slots, a second winding set formed as a second cascaded wire in two other radial layers of the slots, and a jumper connecting the first and second wires. A first winding set may have three cascaded phase wires in first and second layers of the slots, and a second winding set may have three cascaded phase wires in third and fourth layers of the slots. A winding set of a first phase may have a first cascaded wire in two radial layers of a first one of the slots, and a winding set of a second phase may have a second cascaded wire in two other radial layers of the first one of the slots.

First claim

What is claimed is:

1. A stator, comprising:
a substantially cylindrical core having two axial ends and a plurality of longitudinally extending slots formed therebetween;
a first winding set formed as a continuous first wire disposed about substantially the entire circumference of the core, is disposed in a radial layer of a first slot of the plurality of slots and in two radial layers of a second slot of the plurality of slots adjacent to the first slot;
a second winding set formed as a continuous second wire disposed about substantially the entire circumference of the core, is disposed in two other radial layers of the second slot and in a radial layer of a third slot disposed adjacent to the second slot whereby the second slot is disposed between the first and third slots;
wherein the first wire is disposed in one additional layer in one of the first and third slots and the second wire is disposed in one additional layer of the other one of the first and third slots whereby the first wire and second wire are disposed in two layers of the first slot, in four layers in the second slot and in two layers of the third slot;
wherein the first and second wires define at least one 5-7 pitch end loop section wherein, at a first one of the axial ends of the cylindrical core, the first wire defines a first end loop that exits from the first slot and enters an eighth slot disposed seven slots in a first circumferential direction from the first slot whereby there are six slots disposed between the slots exited and entered by the first end loop and wherein, at the first one of the axial ends, the second wire defines a second end loop that exits from the second slot and enters a seventh slot disposed five slots in the first circumferential direction from the second slot whereby there are four slots disposed between the slots exited and entered by the second end loop;
wherein the first and second wires each define 6 pitch end loops on the first one of the axial ends of the cylindrical core on each circumferentially adjacent side of the at least one 5-7 pitch end loop section whereby there are five slots disposed between the slots exited and entered by the first and second wires for each of the 6 pitch end loops; and
wherein the two radial layers in which the first wire is disposed in the second slot are radially innermost and radially third innermost, and wherein the two radial layers in which the second wire is disposed in the second slot are radially second innermost and radially fourth innermost.

2. The stator of claim 1 , wherein one of the first winding set and the second winding set includes a reversing end loop section wherein the circumferential direction of the winding set is reversed.

3. The stator of claim 1 , wherein a jumper connects the first and second wires.

4. The stator of claim 1 , wherein at least one of the first and second wires define at least one 7 pitch end loop section wherein each of the end loops of a set of end loops of the at least one wire exiting from adjacent slots enter slots disposed seven slots in a first circumferential direction from the exited slots whereby there are six slots disposed between the slots exited and entered by each respective one of the set of end loops.

5. The stator of claim 1 , wherein in the first slot, the first wire is disposed in the radially fourth innermost radial layer and the second wire is disposed in the radially third innermost radial layer and wherein, in the third slot, the first wire is disposed in the radially second innermost radial layer and the second wire is disposed in the radially innermost radial layer.

6. The stator of claim 1 , wherein the first wire is in a layer of the first slot and the second wire is in another layer of the first slot and wherein the first wire is in a layer of the third slot and the second wire is in another layer of the third slot.

7. The stator of claim 1 , wherein the second slot contains only a first phase.

8. The stator of claim 7 , wherein the first slot contains the first phase and a second phase and the third slot contains the first phase and a third phase.

9. A stator, comprising:
a substantially cylindrical core having two axial ends and a plurality of longitudinally extending slots formed therebetween;
a first winding set formed as a continuous first wire disposed about substantially the entire circumference of the core, is disposed in a radial layer of a first slot of the plurality of slots and in two radial layers of a second slot of the plurality of slots adjacent to the first slot;
a second winding set formed as a continuous second wire disposed about substantially the entire circumference of the core, is disposed in two other radial layers of the second slot and in a radial layer of a third slot disposed adjacent to the second slot whereby the second slot is disposed between the first and third slots;
wherein the first wire is disposed in one additional layer in one of the first and third slots and the second wire is disposed in one additional layer of the other one of the first and third slots whereby the first wire and second wire are disposed in two layers of the first slot, in four layers in the second slot and in two layers of the third slot;
wherein the first and second wires define at least one 5-7 pitch end loop section wherein, at a first one of the axial ends of the cylindrical core, the first wire defines a first end loop that exits from the first slot and enters an eighth slot disposed seven slots in a first circumferential direction from the first slot whereby there are six slots disposed between the slots exited and entered by the first end loop and wherein, at the first one of the axial ends, the second wire defines a second end loop that exits from the second slot and enters a seventh slot disposed five slots in the first circumferential direction from the second slot whereby there are four slots disposed between the slots exited and entered by the second end loop;
wherein the first and second wires each define 6 pitch end loops on the first one of the axial ends of the cylindrical core on each circumferentially adjacent side of the at least one 5-7 pitch end loop section whereby there are five slots disposed between the slots exited and entered by the first and second wires for each of the 6 pitch end loops;
wherein the second slot contains only a first phase;
wherein the first slot contains the first phase and a second phase and the third slot contains the first phase and a third phase; and
wherein, in the first slot, the two radial layers containing the first and second wires of the first phase are radially innermost and radially second innermost, and wherein, in the third slot, the two radial layers containing the first and second wires of the first phase are radially third innermost and radially fourth innermost.

10. The stator of claim 9 , wherein the first slot contains the first phase and a second phase and the third slot contains a third phase and the first phase.

11. The stator of claim 10 , wherein each of a first plurality of the plurality of slots contains only the first phase, wherein each of a second plurality of the plurality of slots contains the first and second phases, and wherein each of a third plurality of the plurality of slots contains the first and third phases.

12. The stator of claim 11 , wherein every other slot of the plurality of slots contains only the first phase.

13. The stator of claim 1 , wherein every other slot contains only one phase.

14. The stator of claim 1 wherein the first and second winding sets are formed as cascaded continuous wires.

Assignees

• Remy Tech Llc
• Borgwarner Inc

Inventors

• Neet Kirk

Classifications

• H02K3/28 Primary

  Layout of windings or of connections between windings (windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32) · CPC title

• H02K3/12 Primary

  arranged in slots · CPC title

• H02K1/16 Primary

  Stator cores with slots for windings · CPC title