Method for making an electric motor stator
View Patent ↗A technique for making a stator for an electric motor or similar machine includes disposing a plurality of concentric coils in a stator core such that leads exit both ends of the stator core. The coils are disposed in accordance with a winding pattern that is particularly suited for making four-pole, three-phase machines. Certain of the coils are disposed singularly within core slots, while other coils share slots with coils of other winding groups. The coils may be inserted by machine, and in several layers by rotating the stator core between each layer insertion.
1. A method for making a stator, the method comprising:
installing a first set of concentric coil groups through a first end of a stator core, whereby leads of the first set of concentric coils exit the first end of the stator core;
installing a second set of concentric coil groups through a second end of the stator core, whereby leads of the second set of concentric coils exit the second end of the stator core;
installing a third set of concentric coil groups through the first end of the stator core, whereby leads of the third set of concentric coils exit the first end of the stator core; and
installing a fourth set of concentric coil groups through the second end of the stator core, whereby leads of the fourth set of concentric coils exit the second end of the stator core.
2. The method of claim 1 , wherein at least one coil of the third set of concentric coil groups is installed over a coil of the first set of concentric coils in a slot of the stator core.
3. The method of claim 2 , wherein at least one coil of the fourth set of concentric coil groups is installed over a coil of the second set of concentric coils in a slot of the stator core.
4. The method of claim 1 , wherein at least one coil of each coil group is installed in a respective stator slot with a coil of a different coil group.
5. The method of claim 4 , wherein at least one coil of each coil group is installed singularly in a respective stator slot.
6. The method of claim 1 , wherein the coil groups define a four-pole, three-phase stator.
7. The method of claim 1 , wherein the coil groups are disposed in an order of A1, B4, C2, A3, B1, C4, A2, B3, C1, A4, B2, and C3, where A, B and C represent alternating current phases, and 1, 2, 3 and 4 represent coil groups of the first, second, third and fourth sets, respectively.
8. The method of claim 7 , wherein the stator core includes 72 slots and each coil group includes 4 coils.
9. The method of claim 1 , wherein the coil groups are installed in accordance with the following distribution:
1
Ala
2
Alb
3
Alc/B2d
4
Ald/B2c
5
B2b
6
B2a
7
B4a
8
B4b
9
C3d/B4c
10
C3c/B4d
11
C3b
12
C3a
13
C2a
14
C2b
15
Ald/C2c
16
Alc/C2d
17
Alb
18
Ala
19
A3a
20
A3b
21
A3c/B4d
22
A3d/B4c
23
B4b
24
B4a
25
Bla
26
Blb
27
Blc/C2d
28
Bld/C2c
29
C2b
30
C2a
31
C4a
32
C4b
33
A3d/C4c
34
A3d/C4d
35
A3b
36
A3a
37
A2a
38
A2b
39
Bld/A2c
40
Blc/A2d
41
Blb
42
Bla
43
B3a
44
B3b
45
B3c/C4d
46
B3d/C4c
47
C4b
48
C4a
49
Cla
50
Clb
51
Clc/A2d
52
Cld/A2c
53
A2b
54
A2a
55
A4a
56
A4b
57
B3d/A4c
58
B3c/A4d
59
B3b
60
B3a
61
B2a
62
B2b
63
Cld/B2c
64
Clc/B2d
65
Clb
66
Cla
67
C3a
68
C3b
69
C3c/A4d
70
C3d/A4c
71
A4b
72
A4a,
wherein upper case letters A, B, and C indicate respective phases, digits 1, 2, 3 and 4 represent coil groups, and lower case leters a, b, c and d represent individual coils of each group.
10. The method of claim 1 , wherein the stator core is rotated between each installation step.
11. A method for making a four-pole, three-phase stator, the method comprising:
installing a first set of concentric coil groups through a first end of a stator core, whereby leads of the first set of concentric coils exit the first end of the stator core; rotating the stator core;
installing a second set of concentric coil groups through a second end of the stator core, whereby leads of the second set of concentric coils exit the second end of the stator core;
rotating the stator core;
installing a third set of concentric coil groups through the first end of the stator core, whereby leads of the third set of concentric coils exit the first end of the stator core;
rotating the stator core; and
installing a fourth set of concentric coil groups through the second end of the stator core, whereby leads of the fourth set of concentric coils exit the second end of the stator core.
12. The method of claim 11 , wherein the stator core is rotated about a central vertical axis.
13. The method of claim 11 , wherein at least one coil of each group of the second coil group set is installed over a coil of a group of the first coil group set in a respective slot of the stator core.
14. The method of claim 13 , wherein at least one coil of each group of the fourth coil group set is installed over a coil of a group of the third coil group set in a respective slot of the stator core.
15. The method of claim 11 , wherein at least one coil of each group is installed singularly within a respective slot of the stator core.
16. The method of claim 11 , wherein the coil groups are disposed in an order of A1, B4, C2, A3, B1, C4, A2, B3, C1, A4, B2, and C3, where A, B and C represent alternating current phases, and 1, 2, 3 and 4 represent coil groups of the first, second, third and fourth sets, respectively.
17. The method of claim 11 , wherein the stator core includes 72 slots and each coil group includes 4 coils.
18. The method of claim 11 , wherein the coil groups are installed in accordance with the following distribution:
1
Ala
2
Alb
3
Alc/B2d
4
Ald/B2c
5
B2b
6
B2a
7
B4a
8
B4b
9
C3d/B4c
10
C3c/B4d
11
C3b
12
C3a
13
C2a
14
C2b
15
Ald/C2c
16
Alc/C2d
17
Alb
18
Ala
19
A3a
20
A3b
21
A3c/B4d
22
A3d/B4c
23
B4b
24
B4a
25
Bla
26
Blb
27
Blc/C2d
28
Bld/C2c
29
C2b
30
C2a
31
C4a
32
C4b
33
A3d/C4c
34
A3d/C4d
35
A3b
36
A3a
37
A2a
38
A2b
39
Bld/A2c
40
Blc/A2d
41
Blb
42
Bla
43
B3a
44
B3b
45
B3c/C4d
46
B3d/C4c
47
C4b
48
C4a
49
Cla
50
Clb
51
Clc/A2d
52
Cld/A2c
53
A2b
54
A2a
55
A4a
56
A4b
57
B3d/A4c
58
B3c/A4d
59
B3b
60
B3a
61
B2a
62
B2b
63
Cld/B2c
64
Clc/B2d
65
Clb
66
Cla
67
C3a
68
C3b
69
C3c/A4d
70
C3d/A4c
71
A4b
72
A4a,
wherein upper case letters A, B, and C indicate respective phases, digits 1, 2, 3 and 4 represent coil groups, and lower case letters a, b, c and d represent individual coils of each group.