Stator Winding Design Considerations of Electric Motors

5/30/2015 Stator Winding Design Considerations (Electric Motors)
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Stator Winding Design Considerations (Electric
Motors)
5.1.3
Brushless dc motors initially were designed in large numbers for spindle drives in Winchester disk drives. The
early designs were threephase, later moving to twophase and then onephase, due to the very slow startup
requirements, very small friction loads, and the need to reduce unit cost at all levels. The industrial and machine
tool markets started with and continue to use threephase BLDC motors in their variablespeed, variableload,
highstartup applications. The overwhelming popularity of threephase BLDC motors focuses this subsection
toward threephase windings. Many of the initial design activities for various winding patterns can be traced
back to the 1920s and earlier based on work done on threephase ac windings.
This subsection reviews the various winding line connections, the key winding patterns and hookups, various
winding constants, and winding selection and design techniques.
Basic Winding Configurations. There are other basic decisions that must be made by the design engineer before
a BLDC motor design can commence. Previously defined is the number of phases, which is three here. Next in
importance is the number of poles. The use of two poles is waning, and the use of six or eight poles is
increasing. Fourpole BLDC motors are among the most popular used today. Twoand fourpole BLDC motor
designs are used here, but the rules for two and four poles can be extended to higher pole counts. The number of
stator slots (and teeth) and the winding pattern are key design decisions. This section is dedicated to reviewing
the important parameters of these two design decisions.
In a threephase motor there are three windings or phases positioned 120° electrical apart. Figure 5.30 shows the
location of 6 coils in a representative 12slot stator. A twopole rotor (not shown) will rotate as the three
windings are energized in sequence ABC, as AA’, BB’, and then CC are energized sequentially.The three
phase winding always develops positive starting torque, no matter where the rotor starts its motion.
FIGURE 5.30 Basic 3phase winding layout.
http://whatwhenhow.com/electricmotors/statorwindingdesignconsiderationselectricmotors/ 1/12
There are many winding line connections that can be used in threephase drive systems. Figure 5.31 illustrates
the various configurations. The halfwave wye is the simplest threephase line configuration (Fig. 5.31a). It uses
three power lines and one return line (four leads). The excitation is shown adjacent to the schematic in Fig.
5.31a. Only 33 percent (one lead) of the halfwave wye windings are energized at any time in operation. The
second wye winding, the fullwave wye (Fig. 5.31b) has only three leads but 66 percent (two leads) of the
windings are in operation simultaneously. The excitation scheme is shown to the right of the schematic.
The third major winding connection pattern is the delta, shown in Fig. 5.31c. It possesses the same excitation
scheme as the fullwave wye. The delta winding configuration has been used more extensively than the wye in
fractionalhorsepower (<746 W) motor applications.The wye is more popular with the largersized integral
horsepower BLDC motor users. The final winding to be reviewed is the independent winding line connection
(Fig. 5.31d). In this scheme, each winding is independent of its neighbor. The excitation scheme is more
complicated, but each winding can be operated in parallel, thereby distributing the total current. The windings
are still situated 120° electrical away from each other.This winding configuration has seen limited use to date.
The most popular winding line configurations are the fullwave wye and the delta. In a balanced wye
configuration, the line and coil (phase) currents are equal,
FIGURE 5.31 Popular 3phase BLDC motor winding line connections: (a) wye (half wave), (b) wye (full
wave), (c) delta, and (d) independent.
the neutral current is zero, and the linetoline voltage is V3 times the phase voltage. In a balanced delta
connection, the linetoline and coil (phase) voltages are equal, but coil currents are 1/V3 times the linetoline
currents.
Key Winding Patterns. There are many types of winding patterns that can be utilized. Four major winding
patterns are listed here:
1. Constant integral pitch—lap winding (full)
2. Variable pitch—concentric winding
3. Constant fractional pitch—lap winding for even or odd stator slots
4. Halfpitch
Each of these winding patterns has two coils per stator slot. There is one winding type designated, a consequent
pole winding where there is only a single coil per slot. Consequent pole windings are very popular in single
phase ac motors of fractionalhorsepower size.
Table 5.7 is revised from Veinott and Martin (1987). It displays the various stator slot and rotor pole
combinations along with the maximum number of parallel circuit combinations with a specific slot and pole
combination. For purposes of simplicity, either 12 or 24slot stators are used here to illustrate the various
winding patterns. In one case, a 15slot stator is used to illustrate an oddslot fractionalpitch lap winding.
TABLE 5.7 Slots Versus Poles Versus Parallel Hookups Versus Coils per Pole per Phase
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2 Poles 4 Poles 6 Poles

8 Poles
Coils Coils Coils Coils
per per per per
Slots phase phase phase phase
or per per per per
coils Circuits pole Circuits pole Circuits pole Circuits pole
6 2 1 — — —
9 1 — — —
12 2 241 — —
15 1 1 1Y, — —
18 2 3 2 VA 61 —
21 1 3Yi 1 NP* X —
24 2 4 4 2 NP X 8 1
27 1 4Y, 1 2Y4 3 1Y, 11Y8
30 2 5 2 2Y2 NP X 2 1Y4
33 1 1 23/ NP X 1 1%
36 2 6436 2 4 1Y
39 1 1 3Y4 NP X 1 15/8
42 2 7 2 3Y2 NP X 2 13/4
45 1 7Yi 1 33/ 3 2Yi
48 2 8 4 4 NP X 82
If one uses a 12slot stator winding, there are two fullpitch integral lap windings available, one for two poles
and the other for four poles.
P x Ph = nS (5.1)
where P = number of poles Ph = number of phases S = number of stator slots n = integer number 1, 2, 3,… n
If P = 2, Ph = 3, and S = 12, then n = 2, an integer. Figure 5.30 shows the basic windingslot pattern for a 12
slot 2pole 3phase 2coilsperpoleperphase (n = 2) configuration. The coil pattern for this winding
configuration is shown in Figs. 5.32 and 5.33 as a series wye line configuration and as a parallel wye line
configuration, respectively. There are really 12 coils used in this design, but only 6 are shown.There are two 1
to 7throw coils—one inserted on the right side (CW direction), the second inserted on the left side (CCW
direction), and doubles on the other five coils also, inserted as described previously. Note the position of the
teeth for the 12slot stator. The slot pitch (adjacent slot to slot) is 360/12 or 30° mechanical or electrical. The
angular location for the phase 2 winding (CW direction) is only 60°. It is supposed to be 120°. Symmetry solves
the problem if 180° (polarity change) is added to the 60° to achieve 240° mechanical or electrical. So the 1, 2, 3
winding phase hookups displayed in Fig. 5.32 will yield a CCW rotation.
The series and parallel hookup options are very important from a practical aspect of magnet wire size selection.
It is easier to pack smallersized magnet wires in a
FIGURE 5.32 Series hookup for 2pole wyewinding 12slot brushless dc motor.
FIGURE 5.33 Parallel hookup for 2pole 3phase wyewinding 12slot brushless dc motor, constantpitch
lap winding pattern.
BLDC stator slot than larger ones. Since total turns per phase are directly proportional to torque, putting all the
needed turns (N per phase) in a single coil with smaller magnet wires and then paralleling the coils will yield
extra space for more turns. This is a packing factor consideration.
The disadvantage of using parallel coils is that both sets of coil leads must be used to properly connect the coils
(see Fig. 5.33). Figure 5.34 shows a representation of how two coils would be inserted into adjacent stator slots.
Remember that there are 2 slots per coil per phase for this 2pole 12statorslot winding pattern.
FIGURE 5.34 12slot lamination, 2 poles, 3phase constantpitch lap pattern.
Figure 5.35 shows the winding pattern for a constantpitch 4pole 12slot BLDC stator.There is now only one
coil per pole per phase (n = 1) in this winding, as shown in the following equation:
4 poles x 3 phase = 12 slots
n = 1 coil per pole per phase (5.2)
The four coils per phase can be connected as four coils in a series hookup or four coils in a parallel hookup. It is
also possible to connect two coils in series and two coils in parallel to achieve a seriesparallel hookup. Figure
5.36 displays two adjacent coils inserted into the proper stator slots. Note the shorter length of these coils
because the end turns are shorter while the segments of the turns (conductors) within the appropriate stator slots
remain the same length. The shorter the endturn length (which doesn’t create any torque), the better the motor
design.
The variablepitch winding was developed to reduce the stator endturn height caused by the numerous adjacent
coil crossovers by nesting the coils inside each other, as shown in Fig. 5.37. This pattern can be used only when
coils per phase per pole n is 2 or greater. Figure 5.37 displays an n = 3 condition.The actual winding pattern is
shown in Fig. 5.38. Since n = 2, there will be two different winding lengths or
FIGURE 5.35 Winding pattern for a constantpitch 4pole 12slot stator, 3phase hookup, 30°
mechanical, 60° electrical.
FIGURE 5.36 Constantpitch 4pole lap winding pattern with adjacent coil layout.
throws. The following equation describes the method used to determine the two variable winding pitches:
VSP1 = 7 and VSP2 = 5. The average of these two variablepitch coils should equal the integral winding pitch
for a 3phase 2pole 12slot design, which is 6. Figure 5.39 displays the location of two adjacent coils placed in
the proper stator slots. This winding pattern will reduce endturn height and coil lengths by 10 to 15 percent.The
concentric winding with variable pitch has been used extensively in larger integralhorsepower units,
particularly by the various electric winding repair houses.

FIGURE 5.37 Side view of variablepitch concentric winding pattern.
FIGURE 5.38 Variablepitch concentric winding pattern, 2 poles, 3phase series hookup.
FIGURE 5.39 2pole 3phase variablepitch concentric pattern.
The third winding pattern is fractionalpitch winding, which is used in many applications, particularly odd stator
slots where cogging torque must be reduced. Table 5.7 identifies the fractional pitch as 1% for a 15slot 4pole
configuration.This pattern is popular for resolver windings and some lowcog BLDC motors. The following
equation yields the pitch:
Equation (5.5) identifies the winding pitch or throw as either 3 or 4. Three is selected for the pattern shown in
Fig. 5.40.The starting points for the coils must meet the pattern of coil placements shown. This pattern places
two adjacent coils strategically and equidistantly around the stator with each of the three phases having one set
of two adjacent coils and three sets of single coils (pattern from Veinott and Martin, 1987).
FIGURE 5.40 Constant fractionalpitch oddslot 4pole, 3phase series hookup. Recommended coil
groups: 211121112111 = 15.
As with any winding, there are advantages counterbalanced by disadvantages. The following equation defines
the tooth or slot pitch of the 15slot stator.
Now, since this design is a fourpole BLDC design, there are two full electrical cycles for one full mechanical
cycle. The next equation defines the relationship between electrical and mechanical degrees for any fourpole
design.
Degrees electrical = degrees mechanical x number of pole pairs
.. Degrees electrical = 24°x 2 = 48° electrical (5.7)
A 48° electrical pitch does not equal the desired 60° pitch, so there must be torque loss.
Figure 5.41 illustrates the winding pattern for a 12slot 2pole fractionalpitch winding. A full winding pitch
would possess a value of 6 with a throw of 1 to 7. This winding pattern has a winding pitch of 56 (fractional) or
a throw of 1 to 6. This group of fractionalpitch windings has a pitch less than 1 when an even stator slot count
is employed. This winding pattern is used in larger threephase ac motors to decrease the harmonic content of
both the voltage and mmf waveforms. This technique is very similar to that of shortpitch lap windings used in
brush dc motors.
The final winding type is the halfpitch winding, which has the simplest winding pattern. The coil is wound
directly around the stator tooth with a winding pitch of 1

FIGURE 5.41 Constant fractionalpitch evenslot 2pole 3phase series hookup.
and a throw of 1 to 2. It is used extensively in step motors and switchedreluctance motors. It is also used in PM
BLDC motors used in disk drives. A nineslot eightpole winding is very popular, as well as a nineslot six
pole. This winding by definition is also a fractionalpitch winding. It is the most costeffective and simplest
winding with the shortest mean length of turn (MLT) and therefore the lowest resistance per coil. It does suffer
from reduced torque, as all fractional pitch windings do. The various winding factors that determine the reduced
torque values are reviewed in the next subsection.
Winding Factors for Different Winding Patterns. There are a number of winding factors that adjust for the peak
magnetomotive force (mmf) and the windinggenerated flux <) which directly leads to adjustments to the
winding back emf (Ke) and peak developed torque of the BLDC motor. These factors can be identified as
follows:
• Chord factor (pitch factor)
• Distribution factor (breadth factor) ^ Endturn factor (coillength factor)
for a 12slot 2pole 3phase integralpitch winding with 2 slots per pole per phase. Veinott and Martin (1987)
developed a table with the distribution factor for each major winding pattern, summarized in Table 5.8.
Table 5.9 contains the tabulated results for the Kp and Kd values for the six winding patterns presented plus a
24slot 4pole integralpitch winding pattern illustrated
in Fig. 5.42.
TABLE 5.8 Summary of Distribution Factors
Slots per pole per phase, 3 Phase
or coils per group 2 Phase Conventional Consequent pole
1 1.000 1.000 1.000
2 0.924 0.966 0.866
3 0.911 0.960 0.844
4 0.906 0.958 0.837
5 0.904 0.957 0.833
6 0.903 0.956 0.831
CO 0.900 0.955 8.270
1/2 0.911 0.960 0.844
All other fractional 0.900 0.955 0.827
slot windings
TABLE 5.9 Summary of Kp and Kd Factors
Slot Slots per
Stator Winding Winding Winding pitch, pole per
slots Poles type pitch throw ° mechanical phase n Kp KdKp
12 2 Integral 1 17 30 2 0.966 1.000 0.966
12 4 Integral 1 14 30 1 1.000 1.000 1.000
12 2 Variable 1 (average) 18/16 30 2 0.966 1.000 0.966
15 4 Fractional 1/4 14 24 1 1.000 0.924 0.924
12 2 Fractional *8 16 30 1 1.000 0.966 0.966
9 8 Halfpitch 1>8 12 40 1 1.000 0.985 0.985
24 4 Integral 1 17 15 2 0.966 1.000 0.966
Filling the Stator Slots. The first item in filling the stator slot is to compute the area of the slot. There are many
types of stator slot shapes but the trapezoidal (constanttoothwidth) slot shown in Fig. 5.30 and the round
(variabletoothwidth) slot are the most popular slot shapes. One can use basic trigonometry to determine the
slot area or obtain the actual slot area from the lamination vendor.
There are three methods used to compute slot area and the total volume of copper magnet wire used. They use
the following units:
• Square inches (in2)
• Square mils (mil2)
• Circular mils (cmil)
The circular mils method uses the nominal diameter of the insulated wire in mils or thousandths of an inch and
takes the square of this diameter, which is the circular mil value.
Area, cmil = (nominal diameter, mil)2 (5.10)
For 18 AWG (American Wire Gauge), the nominal insulated singlebuild wire diameter from the Phelps Dodge
magnet wire chart (Table 2.76) is 41.8 mil. The
FIGURE 5.42 24 stator slots, 4 poles, 3phase hookups 30° mechanical, 60° electrical.
wire area is 1747 cmil per Eq. (5.10). The square mils value is smaller and can be computed by modifying Eq.
(5.10) to Eq. (5.11). In many cases, the wire charts compute the magnet wire’s nominal diameter without
insulation coating (bare wire diameter). It is strongly recommended that the insulated wire dimensions be used.
The Phelps Dodge magnet wire chart (Table 2.76) also shows wires per square inch. The more important
parameter is turns (conductors) per square inch. It yields the value of total number of turns—or, more
appropriately, conductors—that can be placed in a slot, assuming 100 percent fill. Now, the most copper fill in
terms of a percentage of actual turns per square inch versus 100 percent fill turns per square inch that this author
has actually done by handinsertion methods is 73 percent with 37 AWG and 63 percent with 21 AWG.
The practical limit is somewhere between 40 and 50 percent of this theoretical value depending on the type of
winding machine, tooling used on the winding machine, length of stator stack, size of stator slot, etc. If one
wanted to use 22 AWG, the turns (conductors) per linear inch would be 37.5 and the turns (conductors) per
square inch would be 1410.
Total conductors (theoretical) = (SA) (turn/in2) Total conductors (theoretical) = 0.2192 x 1410 = 309 (5.12)
where SA = slot area
The total conductors must be an even number because 2 conductors equal 1 turn. Here the maximum value is
308 conductors with 22 AWG magnet wire. That would be 308/2 or 154 turns, since two coils are represented in
every stator slot. Based on a practical slot fill of 45 percent, the maximum number of turns would probably be
69.3, or 69 turns per coil. The actual number of turns to achieve the desired performance has not yet been
determined but for the AWG size selected, 69 turns or 138 conductors is the maximum practical limit.
The next important parameter to establish is the coil resistance. First, one must establish the MLT in the stator
coil.
The MLT value is converted into turns per feet to resolve the units and the value of ohms per foot for 22 AWG
is 0.162 Q.
Stator Winding Computations. Two major motor performance parameters are required to be computed in order
to establish overall motor performance. They are the torque constant Kt and the phase resistance ,Rphase. From
these two parameters, all motor performance can be essentially derived.
The Kt value is derived for the case of RMS torque based on a trapezoidal torque versus position profile and
nearperfect commutation. There is an adjustment of 10 percent to achieve a reasonable value for RMS torque.
This value can be adjusted based on actual torque waveforms if required.
The following equation computes the Kt value per phase as described.
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