Application of Standard Three-Phase Stator Frames in Prime Phase Order Multiphase Machine Construction

The application of multiphase machines in high-power applications is now a recognized alternative, thanks to their higher fault-tolerance when compared with standard three-phase systems. Although multiphase machines with multiples of three-phase winding sets have been favored in many applications, literature has shown that machines with a prime number of phases, such as five-phase machines, generally outperform other phase orders especially in terms of machine torque density. One of the major problems when dealing with a prime number of phases either in academic research or industrial applications is the special stator design. This paper provides a general technique to rewind standard off-the-shelf three-phase stator frames with any general prime phase order while preserving the same copper volume. The proposed winding layout is derived using the star of slots theory and the concept of stator winding shifting. Finite element simulations are used to investigate examples with different phase orders, while experimental investigation is carried out to corroborate the proposed concept by rewinding a standard three-phase stator as a five-phase machine.