US-12620857-B2 - Stator winding arrangement with connections for adjacent diamond coils

US12620857B2US 12620857 B2US12620857 B2US 12620857B2US-12620857-B2

Abstract

A stator for an electric machine includes a winding arrangement including a plurality of parallel paths. Each parallel path includes a plurality of coils arranged on the core, each coil defined by coil legs and end turns, the coil legs including left legs and right legs extending through the slots of the core and arranged in layers within the slots. The left legs and right legs of each coil are connected by first end turns at one end of the core and second end turns at an opposite end of the core. The plurality of coils of each parallel path include a first pair of adjacent coils connected in series and a second pair of adjacent coils connected in series. Additionally, an extended coil connection connects the first pair of adjacent coils and the second pair of adjacent coils in series.

Inventors

Kirk Neet
Matthew R. Conner
Joshua B. Lahrman

Assignees

BORGWARNER INC.

Dates

Publication Date: 20260505
Application Date: 20230912

Claims (20)

1 . A stator for an electric machine defining a plurality of poles comprising: a core including a plurality of slots; and a multi-phase winding arrangement positioned on the core, the multi-phase winding formed of a plurality of diamond coils, and each phase of the winding arrangement comprising at least three parallel paths, wherein one of the at least three parallel paths includes: a plurality of coils arranged on the core, each coil defined by coil legs and end turns, the coil legs including left legs and right legs extending through the slots of the core and arranged in layers within the slots, the left legs and the right legs of each coil connected by first end turns at one end of the core and second end turns at an opposite end of the core, the plurality of coils of the parallel path including a first pair of adjacent coils connected in series and a second pair of adjacent coils connected in series, the first pair of adjacent coils and the second pair of adjacent coils associated with four poles of the electric machine; an extended coil connection connecting the first pair of adjacent coils and the second pair of adjacent coils in series, and wherein at least two poles of a same phase but associated with a different parallel path exist between the first pair of adjacent coils and the second pair of adjacent coils.
2 . The stator of claim 1 , wherein the at least three parallel paths equals four parallel paths.
3 . The stator of claim 2 wherein the at least two poles equals two such that exactly two poles exist between the first pair of adjacent coils and the second pair of adjacent coils.
4 . The stator of claim 1 , wherein the first pair of adjacent coils includes a left coil and a right coil connected in series by a left coil lead that extends radially outward from the end turns and is connected to a right coil lead that extends radially outward from the end turns.
5 . The stator of claim 4 , wherein an end of the left coil lead is axially aligned with an end of the right coil lead.
6 . The stator of claim 5 , wherein the left coil lead is welded to the right coil lead.
7 . The stator of claim 1 wherein the extended coil connection extends circumferentially between the first pair of adjacent coils and the second pair of adjacent coils at a position radially outward from the first end turns.
8 . The stator of claim 7 , wherein the extended coil connection extends along an arc that is greater than 90°.
9 . The stator of claim 1 , wherein each parallel path extends between a first lead extending from an outer layer of one of said plurality of slots and a second lead extending from an inner layer of one of said plurality of slots.
10 . The stator of claim 1 wherein the plurality of parallel paths are associated with a plurality of poles for the stator, wherein each pole of the winding arrangement is associated with a pole slot set including at least three contiguous slots defining at least a leftmost slot, a middle slot and a rightmost slot.
11 . The stator of claim 10 , wherein eight layers of conductors are arranged in each slot, and wherein each pole slot set defines a 4-8-4 conductor arrangement such that four conductors of a first parallel path are arranged in inner layers of the leftmost slot, four conductors of the first parallel path are arranged in inner layers of the middle slot, four conductors of a second parallel path are arranged in outer layers of the middle slot, and four conductors of the second parallel path are arranged in outer layers of the rightmost slot.
12 . The stator of claim 10 , wherein six layers of conductors are arranged in each slot, and wherein each pole slot set defines a 3-6-6-6-3 conductor arrangement such that (i) three conductors of a first parallel path are arranged in inner layers of each of the leftmost slot, a left intermediate slot, the middle slot, and a right intermediate slot, and (ii) three conductors of a second parallel path are arranged in outer layers of each of the left intermediate slot, the middle slot, the right intermediate slot, and the rightmost slot.
13 . The stator of claim 1 wherein the adjacent coils are formed from one contiguous wire.
14 . The stator of claim 1 wherein the first parallel path fills an outer half of X pole and an inner half of X+1 pole, and an outer half of Y pole and an inner half of Y+1 pole, where Y does not equal X+1.
15 . A stator for an electric machine comprising: a core including a plurality of slots; and a multi-phase winding arrangement positioned on the core, each phase of the winding arrangement comprising four at least three parallel paths, each parallel path including at least a first pair of adjacent coils connected in series, a second pair of adjacent coils connected in series, and an extended connection connecting the first pair of adjacent coils and the second pair of adjacent coils in series, wherein at least two poles of a same phase associated with the at least three parallel paths exist between the first pair of adjacent coils and the second pair of adjacent coils; wherein coils forming the first pair of adjacent coils and the second pair of adjacent coils are diamond shaped coils; wherein each of the at least three parallel path includes an entry lead and an exit lead; and wherein the entry leads and the exit leads of all of the at least three parallel paths of each phase are arranged along an arc that spans at least 240 degrees around the core.
16 . The stator of claim 15 , wherein the entry leads and the exit leads of all of the at least three parallel paths of each phase are arranged along an arc that spans 315 degrees around the core.
17 . The stator of claim 16 , wherein the first pair of adjacent coils includes a left coil and a right coil connected in series by a left coil lead that extends radially outward from end turns of the first pair of adjacent coils and is connected to a right coil lead that extends radially outward from the end turns of the first pair of adjacent coils, wherein the second pair of adjacent coils includes a left coil and a right coil connected in series by a left coil lead that extends radially outward from end turns of the second pair of adjacent coils and is connected to a right coil lead that extends radially outward from the end turns of the second pair of adjacent coils, and wherein the extended connection extends circumferentially along an arc that is radially outward from the end turns of the first pair of adjacent coils and the second pair of adjacent coils.
18 . The stator of claim 15 , wherein the adjacent coils are formed from one contiguous insulated wire.
19 . The stator of claim 15 wherein the first parallel path fills an outer half of X pole and an inner half of X+1 pole, and an outer half of Y pole and an inner half of Y+1 pole, where Y does not equal X+1.
20 . A stator for an electric machine comprising: a core including a plurality of slots; and a multi-phase winding arrangement positioned on the core, each phase of the winding arrangement comprising a plurality of parallel paths, wherein each parallel path is comprised of a plurality of adjacent coils connected in series, the plurality of adjacent coils of each parallel path including at least a first pair of adjacent coils and a second pair of adjacent coils, wherein an extended coil connection connects the first pair of adjacent coils and the second pair of adjacent coils in series, wherein each phase of the winding arrangement is associated with a plurality of poles and each pole is associated with a pole slot set including at least a leftmost slot, a middle slot, and a rightmost slot, wherein at least two pole slot sets associated with a same phase as the first pair of adjacent coils and the second pair of adjacent coils are located between the first pair of adjacent coils and the second pair of adjacent coils; and wherein, for each pole slot set, (i) coil legs of a first parallel path are positioned in a first half of layers of the leftmost slot and in the first half of layers of the middle slot, and (ii) coil legs of a second parallel path are positioned in a second half of layers of the middle slot and the second half of layers of the rightmost slot.

Description

FIELD The present disclosure relates to the field of electric machines, and more particularly, stator winding arrangements. BACKGROUND Winding arrangements for stators are known, including winding arrangements with diamond-shaped coils. Electric machines that include such winding arrangements are particularly suited for certain applications, but improvements to such electric machines would be advantageous. For example, certain winding arrangements with coils positioned in adjacent slots require a many long connections between the poles of the winding arrangement. Accordingly, it would be advantageous to provide a winding arrangement with coils positioned in adjacent slots, but with and a limited/reduced number of long series connections between poles. Additionally, it would be advantageous to limit the number of welds required for the diamond coil winding arrangement and/or make the welds easy to complete. It would be of additional advantage to provide a balanced winding and/or a winding with a high slots per pole per phase count and multiple parallel paths per phase. SUMMARY In at least one embodiment, a stator for an electric machine defines a plurality of poles. The electric machine includes a core including a plurality of slots and a multi-phase winding arrangement formed of a plurality of diamond coils is positioned on the core. Each phase of the winding arrangement comprise at least three parallel paths. At least one of the parallel paths includes a plurality of coils arranged on the core, and each coil is defined by coil legs and end turns. The coil legs include left legs and right legs extending through the slots of the core and arranged in layers within the slots. The left legs and right legs of each coil are connected by first end turns at one end of the core and second end turns at an opposite end of the core. The plurality of coils of the one parallel path includes a first pair of adjacent coils connected in series and a second pair of adjacent coils connected in series, the first pair of adjacent coils and the second pair of adjacent coils associated with four poles of the electric machine. Additionally, an extended coil connection connects the first pair of adjacent coils and the second pair of adjacent coils in series. An entry lead is provided at one end of the parallel path and an exit lead is provided at the opposite end of the parallel path. At least two poles which are not associated with the parallel path, exist between the entry lead and the exit lead In at least one embodiment, a stator for an electric machine comprises a core including a plurality of slots and a multi-phase winding arrangement positioned on the core. Each phase of the winding arrangement comprises four parallel paths, each parallel path including at least a first pair of adjacent coils connected in series, a second pair of adjacent coils connected in series, and an extended connection connecting the first pair of adjacent coils and the second pair of adjacent coils in series. The first pair of adjacent coils are separated on the core from the second set of adjacent coils. The coils forming the first pair of adjacent coils and the second pair of adjacent coils are diamond shaped coil. Each of the four parallel path includes an entry lead and an exit lead, wherein the entry leads and the exit leads of all four parallel paths of each phase are arranged along an arc that spans at least 240 degrees around the core. In at least one embodiment, a stator for an electric machine includes a core comprising a plurality of slots and a multi-phase winding arrangement positioned on the core. Each phase of the winding arrangement comprises a plurality of parallel paths. Each of the parallel paths is comprised of a plurality of adjacent coils connected in series. Each phase of the winding arrangement is associated with a plurality of poles and each pole is associated with a pole slot set including at least a leftmost slot, a middle slot, and a rightmost slot. For each pole slot set, (i) coil legs of a first parallel path are positioned in a first half of the layers of the leftmost slot and in the first half of the layers of the middle slot, and (ii) coil legs of a second parallel path are positioned in a second half of the layers of the middle slot and the second half of the layers of the rightmost slot. The above described features and advantages, as well as others, will become more readily apparent to those of ordinary skill in the art by reference to the following detailed description and accompanying drawings. While it would be desirable to provide an electric machine that provides one or more of these or other advantageous features as may be apparent to those reviewing this disclosure, the teachings disclosed herein extend to those embodiments which fall within the scope of the appended claims, regardless of whether they include or accomplish one or more of the advantages or features mentioned herein. BRIEF DESCRIPTION OF THE D