US 11,722,028 B2
System for hairpin windings in electric motors
Ruisheng Shi, Montreal (CA)
Assigned to DANA TM4 INC., Boucherville (CA)
Filed by DANA TM4 INC., Boucherville (CA)
Filed on Mar. 30, 2021, as Appl. No. 17/217,960.
Prior Publication US 2022/0320934 A1, Oct. 6, 2022
Int. Cl. H02K 3/28 (2006.01); H02K 3/14 (2006.01)
CPC H02K 3/28 (2013.01) [H02K 3/14 (2013.01)] 16 Claims
OG exemplary drawing
 
1. A system for a stator assembly of an electric motor, comprising:
a plurality of radial slots positioned around an inner cylindrical surface; and
a winding scheme for the stator assembly including alternating positioning of a hairpin wire having a seven slot span and a hairpin wire having a five slot span in four sub-circuits,
wherein each slot of the plurality of radial slots include eight layers including a first, internal layer and an eighth, external layer with each layer formed to accommodate one leg of one of the hairpin wire having the seven slot span and the hairpin wire having the five slot span,
wherein the four sub-circuit are wired into three phases with an output voltage for each phase being equal,
wherein the four sub-circuits are wired into three phases with an output voltage for each phase being equal,
wherein each of a plurality of hairpin legs included within each slot carries current of a same phase,
wherein for each sub-circuit, some hairpin legs in the first, internal layer and the eighth, external layer are not connected to a respective adjacent hairpin leg so as to provide terminal connections for one phase, and
wherein, in a first sub-circuit, a first hairpin leg in the first, internal layer is coupled to a second hairpin leg in a second, external layer to form a first connection, in a second sub-circuit, a third hairpin leg in the first, internal layer is coupled to a fourth hairpin leg in the second, external layer to form a second connection, in a third sub-circuit, a fifth hairpin leg in the first internal layer is coupled to a sixth hairpin leg in the second d, external layer to form a third connection, and in a fourth sub-circuit, a seventh hairpin leg in the first, internal layer is coupled to an eighth hairpin leg in the second, external layer to form a fourth connection, wherein each of the first connection, the second connection, the third connection, and the fourth connection are connected in parallel to a voltage balanced phase circuit.