Description:BACKGROUND
Technical Field
[001] The present disclosure relates to an electric machine, and more specifically relates to a stator of an electric machine.
Description of the Related Art
[002] The growing depletion and pollution of natural resources has driven the development of sustainable alternatives, including Electric Vehicles (EVs), as replacements for internal combustion engine (ICE) vehicles. The rise of electric vehicles (EVs) has led to a lot of research on better electric machine technology. The electric machine creates torque by using current and a magnetic field. That magnetic field can come from a permanent magnet or from an electromagnet (which uses current to make the field).
[003] Electric machines are critical components in diverse applications, ranging from EVs and industrial machinery to household appliances. Automobile manufacturers often select Interior Permanent Magnet Synchronous Motors (IPMSMs) due to their high-power density and wide operating speed range, achieved through reluctance torque and field weakening control. Characteristics of the IPMSMs well-suited for EV applications. Maximizing these advantages requires careful selection of the stator winding configuration, such as distributed or concentrated windings.
[004] FIG. 1 illustrates a conventional stator 102 of a conventional electric machine 100 according to embodiments as disclosed herein. The conventional electric machine 100 includes a conventional stator 102, and a conventional rotor (not shown in the figure). The conventional stator 102 is a stationary part of the conventional electric machine 100. The rotor is a rotating part of the conventional electric machine 100.
[005] The conventional stator 102 includes a plurality of slots 104 (A-N) that are circumferentially disposed inside the conventional stator 102. In one embodiment, the conventional electric machine 100 is a ten-pole and twelve-slot electric machine. The plurality of slots 104 (A-N) includes slots 1 to 12.
[006] The conventional stator 102 includes a three-phase concentrated winding (U phase, V phase, W phase) 106. The three-phase concentrated winding (U phase, V phase, W phase) 106 includes a plurality of coils disposed within the plurality of slots 104 (A-N) in a series connection.
[007] The positive and negative signs on the three-phase concentrated 3-phase windings denote the direction of current flow and the start and end points of U phase, V phase, and W phase. U phase of the three-phase winding 106 starts at U+ and ends with U-. V phase of the three-phase winding 106 starts with V+ and ends with V-. W phase of the three-phase winding 106 starts with W+ and ends with W1-.
[008] U-phase is routed from Coil 1, spanning from Slot 1 to Slot 2, then through Coil 2, which extends from Slot 3 to Slot 2. From there, U-phase continues from Slot 2 to Slot 8. Next, Coil 3 runs from Slot 8 to Slot 9, while Coil 4 extends from Slot 8 to Slot 7. The V and W phases follow a similar winding pattern, maintaining a 120-degree electrical phase difference. Routing the U-phase from Slot 2 to Slot 8 increases the end-turn wire length, significantly enlarging the overhang and leading to ohmic losses.
[009] The conventional electric machine 100 with above-concentrated stator windings and utilizing the series connection presents challenges such as difficulty in automated winding, longer end turns, and increased copper losses compared to concentrated windings. Further, there are significant limitations such as increased higher-order harmonics at the back electromotive force (EMF) under load conditions due to the non-sinusoidal voltage waveform, challenges in thermal management, and increased cogging torque due to a significant increase in end winding length.
[0010] Further, the conventional electric machine 100 is unable to maintain continuous operation and leads to a halt and a loss of performance in the event of failure conditions (e.g., in case of winding failures) due to the absence of redundant windings (E.g., a plurality of three-phase windings). Additionally, using one or more power supplies along with their corresponding controllers significantly increases the complexity and cost of the conventional electric machine 100. Furthermore, when multiple power supplies are involved, with one or more series windings leads to overhang issues.
[0011] In addition to that, with a single neutral point (star configuration), the hotspot at the neutral point creates uneven heat distribution within the stator windings, exacerbating potential winding heating issues. Overheating can degrade motor performance and lifespan, increasing the risk of insulation breakdown and other thermal failures. Winding failure can halt motor operation, significantly impacting vehicle performance. The above-mentioned problems affect overall reliability and customer’s perception of the product. So, the conventional approach is inefficient in solving the above-mentioned problems.
[0012] Accordingly, there remains a need for an improved stator of an electrical machine and therefore addressing the aforementioned issues.
SUMMARY
[0013] In view of the foregoing, an aspect herein provides a stator of an electric machine. The stator of an electric machine includes a first portion and a second portion. The stator includes a plurality of slots, and a plurality of three-phase windings (U phase, V phase, W phase). The plurality of slots is circumferentially disposed on the stator. The plurality of three-phase windings (U phase, V phase, W phase) includes a first set of three-phase windings (U1 phase, V1 phase, W1 phase) and a second set of three-phase windings (U2 phase, V2 phase, W2 phase). The first set of three-phase windings (U1 phase, V1 phase, W1 phase) disposed on the first portion of the stator. Each phase of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) includes a first plurality of coils disposed within the plurality of slots in a concentrated winding pattern. The second set of three-phase windings (U2 phase, V2 phase, W2 phase) disposed on the second portion of the stator. Each phase of the second set of three-phase windings (U2 phase, V2 phase, W2 phase) includes a second plurality of coils disposed within the plurality of slots in a concentrated winding pattern. The first set of three-phase windings (U1 phase, V1 phase, W1 phase) and the second set of three-phase windings (U2 phase, V2 phase, W2 phase) are mechanically isolated by positioning on the first portion of the stator and the second portion of the stator, respectively. The first set of three-phase windings (U1 phase, V1 phase, W1 phase) and the second set of three-phase windings (U2 phase, V2 phase, W2 phase) are connected in parallel.
[0014] In some embodiments, U1 phase of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) starts at U1+ and ends with U1-, V1 phase of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) starts with V1+ and ends with V1-, W1 phase of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) starts with W1+ and ends with W1-.
[0015] In some embodiments, U2 phase of the second set of three-phase windings (U2 phase, V2 phase, W2 phase) starts at U2+ and ends with U2-, V2 phase of the second set of three-phase windings (U2 phase, V2 phase, W2 phase) starts with V2+ and ends with V2-, W2 phase of the second set of three-phase windings (U2 phase, V2 phase, W2 phase) starts with W2+ and ends with W2-.
[0016] In some embodiments, U1-, V1-, and W1- form a first star configuration of the first set of three-phase windings (U1 phase, V1 phase, W1 phase), U2-, V2-, and W2- form a second star configuration of the second set of three-phase windings (U2 phase, V2 phase, W2 phase).
[0017] In some embodiments, the first set of three-phase windings (U1 phase, V1 phase, and W1 phase) and the second set of three-phase windings (U2 phase, V2 phase, and W2 phase) are connected in either a star configuration or a delta configuration.
[0018] Another aspect of the herein provides a stator of an electric machine. The stator of an electric machine includes a first portion and a second portion. The stator includes a plurality of slots, and a plurality of three-phase windings (U phase, V phase, W phase). The plurality of slots is circumferentially disposed on the stator. The plurality of three-phase windings (U phase, V phase, W phase) includes a first set of three-phase windings (U1 phase, V1 phase, W1 phase) and a second set of three-phase windings (U2 phase, V2 phase, W2 phase). The first set of three-phase windings (U1 phase, V1 phase, W1 phase) disposed on the first portion of the stator. Each phase of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) includes a first plurality of coils disposed within the plurality of slots in a concentrated winding pattern. The second set of three-phase windings (U2 phase, V2 phase, W2 phase) disposed on the second portion of the stator. Each phase of the second set of three-phase windings (U2 phase, V2 phase, W2 phase) includes a second plurality of coils disposed within the plurality of slots in a concentrated winding pattern. The first set of three-phase windings (U1 phase, V1 phase, W1 phase) and the second set of three-phase windings (U2 phase, V2 phase, W2 phase) are mechanically isolated by positioning on the first portion of the stator and the second portion of the stator respectively. The first set of three-phase windings (U1 phase, V1 phase, W1 phase) and the second set of three-phase windings (U2 phase, V2 phase, W2 phase) are connected in parallel.
[0019] In some embodiments, U1 phase of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) starts at U1+ and ends with U1-. V1 phase of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) starts with V1+ and ends with V1-. W1 phase of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) starts with W1+ and ends with W1-.
[0020] In some embodiments, U2 phase of the second set of three-phase windings (U2 phase, V2 phase, W2 phase) starts at U2+ and ends with U2-, wherein V2 phase of the second set of three-phase windings (U2 phase, V2 phase, W2 phase) starts with V2+ and ends with V2-, wherein W2 phase of the second set of three-phase windings (U2 phase, V2 phase, W2 phase) starts with W2+ and ends with W2-.
[0021] In some embodiments, U1+ and U2+ are combined as one and taken out as U phase. V1+ and V2+ are combined as one and taken out as V phase. W1+ and W2+ are combined as one and taken out as W phase.
[0022] In some embodiments, U1-, V1-, and W1- form a first star configuration of the first set of three-phase windings (U1 phase, V1 phase, W1 phase), U2-, V2-, and W2- form a second star configuration of the second set of three-phase windings (U2 phase, V2 phase, W2 phase).
[0023] In some embodiments, the first set of three-phase windings (U1, V1, and W1) and the second set of three-phase windings (U2, V2, and W2) are combined and connected to a power supply as phases U, V, and W.
[0024] In some embodiments, the first set of three-phase windings (U1, V1, and W1) and the second set of three-phase windings (U2, V2, and W2) are connected in either a star configuration or a delta configuration.
[0025] In some embodiments, the first set of three-phase windings (U1-phase, V1-phase, W1-phase) and the second set of three-phase windings (U2-phase, V2-phase, W2-phase) are connected to the single power supply source, allowing current switching between the first set of three-phase windings and the second set of three-phase windings to ensure continuous operation even when failure occurs in at least one of the first set of three-phase windings (U1-phase, V1-phase, W1-phase) and the second set of three-phase windings (U2-phase, V2-phase, W2-phase).
[0026] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF FIGURES
[0027] These and other features, aspects, and advantages of the present invention are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0028] FIG. 1 illustrates a conventional stator of a conventional electric machine according to embodiments as disclosed herein;
[0029] FIG. 2 illustrates a stator of an electric machine according to embodiments as disclosed herein;
[0030] FIG. 3A illustrates a dual star configuration of a first set of the three-phase windings (U1 phase, V1 phase, W1 phase) and a second set of the three-phase windings (U2 phase, V2 phase, W2 phase) of the stator of the electric machine according to embodiments as disclosed herein; and
[0031] FIG. 3B illustrates the dual star configuration of the first set of the three-phase windings (U1 phase, V1 phase, W1 phase) and the second set of the three-phase windings (U2 phase, V2 phase, W2 phase) of the stator of the electric machine with one or more switches according to embodiments as disclosed herein.
[0032] It may be noted that to the extent possible, like reference numerals have been used to represent like elements in the drawing. Further, those of ordinary skill in the art will appreciate that elements in the drawing are illustrated for simplicity and may not have been necessarily drawn to scale. For example, the dimension of some of the elements in the drawing may be exaggerated relative to other elements to help to improve the understanding of aspects of the invention. Furthermore, the elements may have been represented in the drawing by conventional symbols, and the drawings may show only those specific details that are pertinent to the understanding of the embodiments of the invention so as not to obscure the drawing with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

DETAILED DESCRIPTION OF INVENTION
[0033] In the following description, for the purposes of explanation, various specific details are set forth in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent, however, that embodiments of the present disclosure may be practiced without these specific details. Several features described hereafter can each be used independently of one another or with any combination of other features. An individual feature may not address all of the problems discussed above or might address only some of the problems discussed above. Some of the problems discussed above might not be fully addressed by any of the features described herein.
[0034] The ensuing description provides exemplary embodiments only and is not intended to limit the scope, applicability, or configuration of the disclosure. Rather, the ensuing description of the exemplary embodiments will provide those skilled in the art with an enabling description for implementing an exemplary embodiment. It should be understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the disclosure as set forth.
[0035] The word “exemplary” and/or “demonstrative” is used herein to mean serving as an example, instance, or illustration. For the avoidance of doubt, the subject matter disclosed herein is not limited by such examples. In addition, any aspect or design described herein as “exemplary” and/or “demonstrative” is not necessarily to be construed as preferred or advantageous over other aspects or designs, nor is it meant to preclude equivalent exemplary structures and techniques known to those of ordinary skill in the art. Furthermore, to the extent that the terms “includes,” “has,” “contains,” and other similar words are used in either the detailed description or the claims, such terms are intended to be inclusive—in a manner similar to the term “comprising” as an open transition word—without precluding any additional or other elements.
[0036] Reference throughout this specification to “one embodiment” or “an embodiment” or “an instance” or “one instance” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[0037] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
[0038] The accompanying drawings are used to help easily understand various technical features and it should be understood that the embodiments presented herein are not limited by the accompanying drawings. As such, the present disclosure should be construed to extend to any alterations, equivalents, and substitutes in addition to those which are particularly set out in the accompanying drawings. Although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are generally only used to distinguish one element from another.
[0039] In view of the foregoing, an aspect herein provides a stator of an electric machine. The stator of an electric machine includes a first portion and a second portion. The stator includes a plurality of slots, and a plurality of three-phase windings (U phase, V phase, W phase). The plurality of slots is circumferentially disposed on the stator. The plurality of three-phase windings (U phase, V phase, W phase) includes a first set of three-phase windings (U1 phase, V1 phase, W1 phase) and a second set of three-phase windings (U2 phase, V2 phase, W2 phase). The first set of three-phase windings (U1 phase, V1 phase, W1 phase) is disposed on the first portion of the stator.
[0040] Each phase of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) includes a first plurality of coils disposed within the plurality of slots in a concentrated winding pattern. The second set of three-phase windings (U2 phase, V2 phase, W2 phase) is disposed on the second portion of the stator. Each phase of the second set of three-phase windings (U2 phase, V2 phase, W2 phase) includes a second plurality of coils disposed within the plurality of slots in a concentrated winding pattern. The first set of three-phase windings (U1 phase, V1 phase, W1 phase) and the second set of three-phase windings (U2 phase, V2 phase, W2 phase) are mechanically isolated by positioning on the first portion of the stator and the second portion of the stator respectively. The first set of three-phase windings (U1 phase, V1 phase, W1 phase) and the second set of three-phase windings (U2 phase, V2 phase, W2 phase) are connected in parallel.
[0041] As mentioned, there remains a need for an improved stator of an electrical machine. Referring now to the drawings, and more particularly to FIGS. 1 to 3 where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments.
[0042] FIG. 2 illustrates a stator 202 of an electric machine 200 according to embodiments as disclosed herein. The electric machine 200 includes a stator 202 and a rotor (not shown in the figure). The stator 202 is a stationary part of the electric machine 200. The rotor is a rotating part of the electric machine 200. The stator 202 includes a plurality of slots 204 (A-N) that are circumferentially disposed inside the stator 202. In one embodiment, the electric machine 200 is a ten-pole and twelve-slot electric machine. The plurality of slots 204 (A-N) includes slot 1 to slot 12. The stator 202 includes a first portion 202A and a second portion 202B. In one embodiment, the first portion 202A and the second portion 202B positioned 180° apart.
[0043] The stator 202 includes a plurality of three-phase windings (U phase, V phase, W phase) 206. The plurality of three-phase windings (U phase, V phase, W phase) 206 includes a first set of three-phase windings (U1 phase, V1 phase, W1 phase) 206A and a second set of three-phase windings (U2 phase, V2 phase, W2 phase) 206B. The first set of three-phase windings (U1 phase, V1 phase, W1 phase) 206A and the second set of three-phase windings (U2 phase, V2 phase, W2 phase) 206B are mechanically isolated from each other. The first set of three-phase windings (U1 phase, V1 phase, W1 phase) 206A is positioned on the first portion 202A of the stator 202. The second set of three-phase windings (U2 phase, V2 phase, W2 phase) 206B is positioned on the second portion 202B of the stator 202.
[0044] The first set of three-phase windings (U1 phase, V1 phase, W1 phase) 206A includes a first plurality of coils disposed within the plurality of slots 204 (A-N) in a concentrated winding pattern. The second set of three-phase windings (U2 phase, V2 phase, W2 phase) 206B includes a second plurality of coils disposed within the plurality of slots 204 (A-N) in a concentrated winding pattern. The first set of three-phase windings (U1 phase, V1 phase, W1 phase) 206A and the second set of three-phase windings (U2 phase, V2 phase, W2 phase) 206B are connected in parallel using a dual star configuration. In one embodiment, the first set of three-phase windings (U1 phase, V1 phase, W1 phase) 206A and the second set of three-phase windings (U2 phase, V2 phase, W2 phase) 206B are connected in parallel using a dual delta configuration.
[0045] The positive and negative signs on the first and second plurality of coils denote the direction of current flow and the start and end points of U1, V1, W1, U2, V2, and W2. U1 phase of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) 206A starts at U1+ and ends with U1-. V1 phase of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) 206A starts with V1+ and ends with V1-. W1 phase of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) 206A starts with W1+ and ends with W1-. U2 phase of the second set of three-phase windings (U2 phase, V2 phase, W2 phase) 206B starts at U2+ and ends with U2-. V2 phase of the second set of three-phase windings starts (U2 phase, V2 phase, W2 phase) 206B with V2+ and ends with V2-. W2 phase of the second set of three-phase windings (U2 phase, V2 phase, W2 phase) 206B starts with W2+ and ends with W2-.
[0046] FIG. 3A illustrates a dual star configuration 300 of the first set of the three-phase windings (U1 phase, V1 phase, W1 phase) 206A and the second set of the three-phase windings (U2 phase, V2 phase, W2 phase) 206B of the stator 202 of the electric machine 200 according to embodiments as disclosed herein. U1-, the V1-, and the W1- of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) 206A form a first star configuration 302. The U2-, the V2-, and the W2- of the second set of three-phase windings (U2 phase, V2 phase, W2 phase) 206B form a second star configuration 304. The U1+ and the U2+ are the other ends of U1- and the U2-. The V1+ and the V2+ are the other ends of the V1-, and the V2-. The W1+ and W2+ are the other ends of the W1- and the W2-.
[0047] The U1+ and U2+ are combined as one and taken out as the U phase. The V1+ and V2+ are combined as one and taken out as the V phase. The W1+ and W2+ are combined as one and taken out as the W phase. The first set of three-phase windings (U1, V1, and W1) 206A and the second set of three-phase windings (U2, V2, and W2) 206B are combined and connected to a power supply as phases U, V, and W 306. Further, the dual star configuration 300 includes a first neutral point and a second neutral point.
[0048] For the 10 poles, 12 slots electric machine, the U1+, V1+, and W1+ are taken from the slot 1, slot 4, and slot 5 of the first portion of the stator 202A respectively. U1-, the V1-, and the W1- are taken out from the slot 2, slot 3, and slot 6. Furthermore, the U2+, V2+, and W2+ are taken from the slot 8, slot 9, and slot 12 of the second portion of the stator 202B respectively. The U2-, the V2-, and the W2- are taken out from the slot 7, slot 10, and slot 11. In one embodiment, the first set of three-phase windings (U1 phase, V1 phase, W1 phase) 206A and the second set of three-phase windings (U2 phase, V2 phase, W2 phase) 206A are connected in either a star configuration or a delta configuration. In another aspect, the electric machine 200 is not restricted to a specific number of poles and slots and can be any type of electric machine.
[0049] The first set of three-phase windings (U1-phase, V1-phase, W1-phase) 206A and the second set of three-phase windings (U2-phase, V2-phase, W2-phase) 206B are connected to the single power supply source for allowing current switching between the first set of three-phase windings 206A and the second set of three-phase windings 206B to ensure continuous operation even when failure occurs in at least one of the first set of three-phase windings (U1-phase, V1-phase, W1-phase) 206A and the second set of three-phase windings (U2-phase, V2-phase, W2-phase) 206B.
[0050] FIG. 3B illustrates the dual star configuration 300 of the first set of the three-phase windings (U1 phase, V1 phase, W1 phase) 206A and the second set of the three-phase windings (U2 phase, V2 phase, W2 phase) 206B of the stator 202 of the electric machine 200 with a control unit 308 according to embodiments as disclosed herein.
[0051] The control unit 308 includes one or more switches 310 (A-N), and one or more sensors (not shown in the figure). The control unit 308 is configured to monitor and diagnose one or more faults (E.g., open circuit, or short circuit) in the first set of three-phase windings (U1 phase, V1 phase, W1 phase) 206A and the second set of three-phase windings (U2 phase, V2 phase, W2 phase) 206B. The redundant windings (the first set of three-phase windings (U1 phase, V1 phase, W1 phase) 206A and the second set of three-phase windings (U2 phase, V2 phase, W2 phase) 206B) are connected to the control unit as inputs (U1, U2, V1, V2, W1, and W2).
[0052] The redundant windings (the first set of three-phase windings (U1 phase, V1 phase, W1 phase) 206A and the second set of three-phase windings (U2 phase, V2 phase, W2 phase) 206B) designed to enhance fault tolerance and ensure uninterrupted operation of the electric machine 200 even when either the first set of three-phase windings or the second set of three-phase windings experience a fault, such as a short circuit or open circuit.
[0053] Under normal operation (the one or more switches 310 (A-N) are in a closed state, the first set of three-phase windings (U1, V1, W1) 206A and the second set of three-phase windings (U2, V2, W2) 206B work together to power the electric machine 200. If a fault is detected in either the first set of three-phase windings (U1, V1, W1) 206A or the second set of three-phase windings (U2, V2, W2) 206B using the one or more sensors then the faulty winding is deactivated by the control unit 308 by using the one or more switches 310 (A-N). The remaining operational winding set continues to power the electric machine 200 at a reduced torque and power output.
[0054] For example, when a fault occurs in U1, V1, or W1 phases of the first set of three-phase windings (U1, V1, W1) 206A, the control unit 308 deactivates the first set of three-phase windings (U1, V1, W1) 206A by opening corresponding switches 310A, 310C, 310E of the one or more switches 310 (A-N). The second set of three-phase windings (U2, V2, W2) 206B continues to operate the electric machine 200. Similarly, when a fault occurs in U2, V2, or W2 phases of the second set of three-phase windings (U2, V2, W2) 206B, the control unit 308 deactivates the second set of three-phase windings (U2, V2, W2) 206B by opening corresponding switches of the one or more switches 310B, 310D, 310F of the one or more switches 310 (A-N). The first set of three-phase windings 206A (U1, V1, W1) continues to operate the electric machine 200.
[0055] In the event of the fault, the electric machine 200 remains operational at a reduced capacity, effectively minimizing downtime and ensuring system reliability. The proposed configuration of the plurality of three-phase windings with a concentrated winding pattern significantly enhances the electric machine’s 200 fault tolerance, making the electric machine 200 well-suited for applications requiring continuous operation and minimal motor downtime, especially electric vehicles.
[0056] In one aspect of the present disclosure, the plurality of three-phase windings (U phase, V phase, W phase) 206 includes the n-th set of three-phase windings (Un phase, Vn phase, Wn phase). In one aspect of the present disclosure, the stator 202 may include N number portions 202N. In addition to that, the number of poles and slots of the stator 202 may vary based on the requirement and application.
[0057] The proposed approach employs the plurality of three phase windings that includes the first set of three-phase windings (U1 phase, V1 phase, W1 phase) 206A and the second set of three-phase winding (U2 phase, V2 phase, W2 phase) 206B. Further, the stator 202 includes the first portion 202A and the second portion 202B to separate the first set of three-phase windings (U1 phase, V1 phase, W1 phase) 206A and the second set of three-phase winding (U2 phase, V2 phase, W2 phase) 206B for effectively reducing the overhang. The decreased overhang leads to a reduction in impedance. As the impedance value is reduced, the resistance value decreases, consequently reducing copper losses. As a result, the overhang in the parallel winding is reduced significantly. Reduction in losses ultimately improves the overall motor efficiency.
[0058] In addition to that, the present approach includes dual isolated star configurations, which reduce the heat generated by copper losses (I²R losses). The heat generated is located at the first and second neutral points of the star dual configuration and can be effectively cooled by creating a path for heat dissipation through the dual star configurations, ensuring more efficient operation and improved thermal management.
[0059] The proposed approach employs parallel winding instead of the series winding connection, resulting in a more efficient distribution of the windings, which aids in balancing the magnetic fields and minimizing the distortion that typically leads to the generation of harmonics. By utilizing parallel winding, multiple winding paths are created, resulting in a smoother flux distribution, thereby reducing higher-order odd harmonics, such as the 3th and 7th harmonics. Furthermore, the parallel winding configuration ensures that higher torque is maintained even at high speeds, enabling efficient high-speed operation and enhancing the motor's performance. As a result, harmonics in the back EMF at load conditions by using the parallel winding are reduced significantly.
[0060] The electric machine 200 employs the plurality of three-phase concentrated windings (the first set of three-phase windings (U1 phase, V1 phase, W1 phase) 206A and the second set of three-phase windings (U2 phase, V2 phase, W2 phase) 206B) arranged in parallel sets with a dual star configuration. In the proposed approach, the stator 202 includes the first portion 202A and the second portion 202B to separate the first set of three-phase windings (U1 phase, V1 phase, W1 phase) 206A and the second set of three-phase winding (U2 phase, V2 phase, W2 phase). At the same time, the first set of three-phase windings (U1 phase, V1 phase, W1 phase) 206A and the second set of three-phase windings (U2 phase, V2 phase, W2 phase) 206B are connected in a parallel configuration.
[0061] The first set of three-phase windings (U1 phase, V1 phase, W1 phase) 206A and the second set of three-phase windings (U2 phase, V2 phase, W2 phase) 206B are connected to a single power supply source which allows for the switching of currents in the individual windings, for ensuring continued operation even if one of the winding sets fails. So, the dual winding configuration provides inherent redundancy, guaranteeing continued motor operation despite a single winding fault, thereby increasing system robustness and efficiency. Furthermore, this configuration contributes to improved performance through reduced overhang, harmonic content, and enhanced thermal management. Further simplified winding patterns with the use of concentrated winding patterns enable ease of manufacturing when it comes to automated winding.
[0062] In addition, the electric machine 200 features a simpler construction and lower cost, as the electric machine 200 operates with the single power supply and requires only a single controller, unlike the conventional electric machine 100. Moreover, the use of the single power supply with redundant windings in the electric machine 200 eliminates overhang issues.
[0063] The simplified and regular coil winding pattern enables the adoption of automated winding technologies and facilitates faster, more cost-effective, and consistent manufacturing processes, optimizing the design for high-volume production.
[0064] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the appended claims. Improvements and modifications may be incorporated herein without deviating from the scope of the invention.

 
LIST OF REFERENCE NUMERALS

Electric machine 200.
Stator 202.
First portion 202A.
Second portion 202B.
Plurality of slots 204 (A-N)
Plurality of three-phase windings 206.
First set of three-phase windings 206A.
Second set of three-phase windings 206B.
First star configuration 302.
Second star configuration 304.
Control Unit 308.
One or more switches 310 (A-N).
, Claims:CLAIMS
I/We claim:

1. A stator (202) of an electrical machine (200), wherein the stator (202) includes a first portion (202A), and a second portion (202B) comprising:
a plurality of slots (204 (A-N)) that are circumferentially disposed on the stator (202); and
a plurality of three-phase windings (U phase, V phase, W phase) (206) comprises:
a first set of three-phase windings (U1 phase, V1 phase, W1 phase) (206A) disposed on the first portion (202A) of the stator (202), wherein each phase of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) (206A) comprises a first plurality of coils disposed within the plurality of slots (204 (A-N)) in a concentrated winding pattern;
a second set of three-phase windings (U2 phase, V2 phase, W2 phase) (206B) disposed on the second portion (202B) of the stator (202), wherein each phase of the second set of three-phase windings (U2 phase, V2 phase, W2 phase) (206B) comprises a second plurality of coils disposed within the plurality of slots (204 (A-N)) in a concentrated winding pattern,
wherein the first set of three-phase windings (U1 phase, V1 phase, W1 phase) (206A) and the second set of three-phase windings (U2 phase, V2 phase, W2 phase) (206B) are mechanically isolated by positioning on the first portion (202A) of the stator (202) and the second portion (202B) of the stator (202) respectively, wherein the first set of three-phase windings (U1 phase, V1 phase, W1 phase) (206A) and the second set of three-phase windings (U2 phase, V2 phase, W2 phase) (206B) are connected in parallel.

2. The stator (202) as claimed in claim 1, wherein U1 phase of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) (206A) starts at U1+ and ends with U1-, wherein V1 phase of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) (206A) starts with V1+ and ends with V1-, wherein W1 phase of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) (206A) starts with W1+ and ends with W1-.

3. The stator (202) as claimed in claim 1, wherein U2 phase of the second set of three-phase windings (U2 phase, V2 phase, W2 phase) (206B) starts at U2+ and ends with U2-, wherein V2 phase of the second set of three-phase windings (U2 phase, V2 phase, W2 phase) (206B) starts with V2+ and ends with V2-, wherein W2 phase of the second set of three-phase windings (U2 phase, V2 phase, W2 phase) (206B) starts with W2+ and ends with W2-.

4. The stator (202) as claimed in claims 2 and 3, wherein U1-, V1-, and W1- form a first star configuration (302) of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) (206A), wherein U2-, V2-, and W2- form a second star configuration (304) of the second set of three-phase windings (U2 phase, V2 phase, W2 phase) (206B).

5. The stator (202) as claimed in claim 1, wherein the first set of three-phase windings (U1 phase, V1 phase, and W1 phase) (206A) and the second set of three-phase windings (U2 phase, V2 phase, and W2 phase) (206B) are connected in either a star configuration or a delta configuration.

6. A stator (202) of an electrical machine (200), wherein the stator (202) includes a first portion (202A), and a second portion (202B) comprising:
a plurality of slots (204 (A-N)) that are circumferentially disposed on the stator (202); and
a plurality of three-phase windings (U phase, V phase, W phase) (206) comprises:
a first set of three-phase windings (U1 phase, V1 phase, W1 phase) (206A) disposed on the first portion (202A) of the stator (202), wherein each phase of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) (206A) comprises a first plurality of coils disposed within the plurality of slots (204 (A-N)) in a concentrated winding pattern;
a second set of three-phase windings (U2 phase, V2 phase, W2 phase) (206B) disposed on the second portion (202B) of the stator (202), wherein each phase of the second set of three-phase windings (U2 phase, V2 phase, W2 phase) (206B) comprises a second plurality of coils disposed within the plurality of slots (204 (A-N)) in a concentrated winding pattern,
wherein the first set of three-phase windings (U1 phase, V1 phase, W1 phase) (206A) and the second set of three-phase windings (U2 phase, V2 phase, W2 phase) (206B) are mechanically isolated by positioning on the first portion (202A) of the stator (202) and the second portion (202B) of the stator (202) respectively, wherein the first set of three-phase windings (U1 phase, V1 phase, W1 phase) (206A) and the second set of three-phase windings (U2 phase, V2 phase, W2 phase) (206B) are connected in parallel.

7. The stator (202) as claimed in claim 6, wherein U1 phase of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) (206A) starts at U1+ and ends with U1-, wherein V1 phase of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) (206A) starts with V1+ and ends with V1-, wherein W1 phase of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) (206A) starts with W1+ and ends with W1-.

8. The stator (202) as claimed in claim 6, wherein U2 phase of the second set of three-phase windings (U2 phase, V2 phase, W2 phase) (206B) starts at U2+ and ends with U2-, wherein V2 phase of the second set of three-phase windings (U2 phase, V2 phase, W2 phase) (206B) starts with V2+ and ends with V2-, wherein W2 phase of the second set of three-phase windings (U2 phase, V2 phase, W2 phase) (206B) starts with W2+ and ends with W2-.


9. The stator (202) as claimed in claims 7 and 8, wherein U1-, V1-, and W1- form a first star configuration (302) of the first set of three-phase windings (U1 phase, V1 phase, W1 phase) (206A), wherein U2-, V2-, and W2- form a second star configuration (304) of the second set of three-phase windings (U2 phase, V2 phase, W2 phase) (206B).

10. The stator (202) as claimed in claim 6, wherein the first set of three-phase windings (U1 phase, V1 phase, and W1 phase) (206A) and the second set of three-phase windings (U2 phase, V2 phase, and W2 phase) (206B) are connected in either a star configuration or a delta configuration.

11. The stator (202) as claimed in claim 6, wherein the stator (202) further comprises a control unit (308), wherein the control unit (308) comprises one or more sensors and one or more switches (310 (A-N)), wherein U1 phase, U2 phase, V1 phase, V2 phase, W1 phase, and W2 phase are connected to the control unit (308) as inputs and taken out as outputs U, V, W.

12. The stator (202) as claimed in claim 11, wherein the one or more sensors are configured to identify one or more faults in the first set of three-phase windings (U1 phase, V1 phase, W1 phase) 206A and the second set of three-phase windings (U2 phase, V2 phase, W2 phase) 206B, wherein the one or more switches (310 (A-N)) are configured to deactivate the faulty winding from the first set of three-phase windings (U1 phase, V1 phase, W1 phase) 206A and the second set of three-phase windings (U2 phase, V2 phase, W2 phase) 206B.


13. The stator (202) as claimed in claim 6, wherein the first set of three-phase windings (U1-phase, V1-phase, W1-phase) (206A) and the second set of three-phase windings (U2-phase, V2-phase, W2-phase) (206B) are connected to a single power supply via the control unit (308) to ensure continuous operation even when failure occurs in at least one of the first set of three-phase windings (U1-phase, V1-phase, W1-phase) (206A) and the second set of three-phase windings (U2-phase, V2-phase, W2-phase) (206B).