Self-resonance coil winding method and low-reluctance generator coil winding

Abstract

The invention belongs to the technical field of inductor and generator manufacturing, and particularly relates to a self-resonance coil winding method and a low-reluctance generator coil winding. A same-direction lamination winding method is adopted, a wire is fixed at a starting point, N turns are wound to form a first layer of a coil, then the first layer of the coil is attached, M turns are wound in the same direction, the first layer is overlapped, a second layer of the coil is formed, then the second layer of the coil is attached, X turns are wound in the same direction, the second layer is overlapped, and the third layer of the coil is formed. And winding the fourth layer, the fifth layer to the Yth layer according to the same rule. The layers of the finished coil are connected in series and are stacked into a whole layer by layer. By improving the winding method of the coil, the magnetic poles of the generator generate magnetoelectric energy standing waves and voltage and current phase shifts, so that the magnetic resistance of the stator magnetic poles of the generator to the rotation of the rotor is reduced, and the efficiency of converting mechanical energy into electric energy of the generator is greatly improved.

Description

Technical Field

[0001] This invention belongs to the field of inductor and generator manufacturing technology, specifically relating to a self-resonant coil winding method and a low magnetic reluctance generator coil winding. Background Technology

[0002] There are many types of generators, but their working principles are all based on the laws of electromagnetic induction and electromagnetic force. The general principle of their construction is to use appropriate magnetic and electrical materials to form magnetic circuits and electrical circuits that induce each other electromagnetically in order to generate electromagnetic power and achieve the purpose of energy conversion.

[0003] Various commercial generators have traditionally used the law of electromagnetic force to generate electricity by cutting magnetic lines of force. The rotor or stator is pre-installed with permanent magnets or electromagnetic devices. The rotor's rotation cuts magnetic lines of force to generate electricity. However, the efficiency of converting mechanical energy into electrical energy is low. Regardless of advancements in materials technology or optimization of mechanical structures, the current conversion rate of mechanical energy to electrical energy in generators is typically only around 72%. In the 1980s, a generator manufacturer in a certain country spent 10 years increasing the conversion rate of mechanical energy to electrical energy in small generators from 79% to 80%. More than 30 years have passed since then, and multiple factors, including principles, materials, and technology, have limited the conversion rate of mechanical energy to electrical energy in generators to below 80%.

[0004] Traditional generator coils mostly use helical reciprocating winding or bundled winding, and there has been no improvement for over a hundred years. In recent years, generator coil winding technology with "U-shaped hairpin" installation has appeared on the market. However, the technical principle is still limited to cutting magnetic lines of force, and the efficiency of converting mechanical energy into electrical energy has not been improved. There is an urgent need for technology that can significantly improve generator efficiency. Summary of the Invention

[0005] To address the problem of low efficiency in converting mechanical energy into electrical energy in generators, the inventor applied his original physics research results to integrate inductor and capacitor manufacturing technology and circuit design technology into generator design and manufacturing. He designed a self-resonant coil winding method and a low magnetic reluctance generator coil winding. By improving the winding method of the generator coil winding, the generator rotor can rotate in a low magnetic reluctance state, which greatly improves the efficiency of converting mechanical energy into electrical energy in generators.

[0006] A method for winding a self-resonant coil, specifically a unidirectional multilayer winding method, is as follows:

[0007] Fix the wire at the starting point, bundle or spirally reciprocate N turns to form the first layer of the coil, then attach the first layer of the coil and bundle or spirally reciprocate M turns, superimpose on the first layer to form the second layer of the coil, then attach the second layer of the coil and bundle or spirally reciprocate X turns, superimpose on the second layer to form the third layer of the coil, and wind the fourth, fifth and so on up to the Yth layer in the same way;

[0008] The layers of the finished coil are connected in series and stacked together. When current flows through the coil, the magnetic field direction of each winding layer is the same, as determined by the right-hand screw rule.

[0009] Furthermore, the same-direction stacked winding method uses clockwise or counterclockwise winding; after the layers of the finished coil are connected in series, the continuous winding direction of the conductor is consistent. When the current flows through the coil, the magnetic field direction of each winding layer is the same, as determined by the right-hand screw rule.

[0010] Furthermore, the conductor may be a single strand or a bundle of multiple strands used as a single conductor.

[0011] Furthermore, the finished coil is wound on a magnetic core or wound in a hollow core.

[0012] A low reluctance generator coil winding is formed by winding a coil with three or more layers using a self-resonant coil winding method to form a self-resonant coil; the self-resonant coil is installed on the generator or directly wound on the generator, and is connected in series, parallel or a combination of series and parallel to form the low reluctance generator coil winding.

[0013] Preferably, three or more coils wound using a bundled winding or helical reciprocating winding method are stacked into one unit. They are connected in series, layer by layer, and stacked in a way that the magnetic field direction of each winding layer is the same when current flows through the coil, as determined by the right-hand screw rule. The stacked coils are installed on the generator and connected in series, parallel, or a combination of series and parallel to form the low magnetic reluctance generator coil winding.

[0014] The beneficial effects of this invention are:

[0015] The low-resistivity generator coil windings wound using the self-resonant coil winding method of this invention can significantly improve the efficiency of converting mechanical energy into electrical energy, greatly reduce power generation costs, and enhance the economic and environmental benefits for society as a whole. The physical characteristics of the inductor disclosed in this invention open up broader fields and application prospects for the development and application of inductor technology. Attached Figure Description

[0016] Figure 1 This is an exploded view of the structure of a self-resonant coil according to one embodiment of the present invention.

[0017] In the attached diagram: 1 - first layer of coil, 2 - second layer of coil, 3 - third layer of coil. Detailed Implementation

[0018] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. These embodiments are described in sufficient detail to enable those skilled in the art to understand and practice the invention. Logical, implementation, and other changes may be made to the embodiments without departing from the spirit and scope of the invention. Therefore, the following detailed description should not be construed as limiting, and the scope of the invention is defined solely by the claims.

[0019] A method for winding a self-resonant coil, specifically a unidirectional multilayer winding method, is as follows:

[0020] Fix the wire at the starting point, bundle or spirally reciprocate N turns to form the first layer of the coil, then attach the first layer of the coil and bundle or spirally reciprocate M turns, superimpose on the first layer to form the second layer of the coil, then attach the second layer of the coil and bundle or spirally reciprocate X turns, superimpose on the second layer to form the third layer of the coil, and wind the fourth, fifth and so on up to the Yth layer in the same way;

[0021] The layers of the finished coil are connected in series and stacked together. When current flows through the coil, the magnetic field direction of each winding layer is the same, as determined by the right-hand screw rule.

[0022] The same-direction stacked winding method uses clockwise or counterclockwise winding. After the layers of the finished coil are connected in series, the continuous winding direction of the conductor is consistent. When the current flows through the coil, the magnetic field direction of each winding layer is the same according to the right-hand screw rule.

[0023] The conductor can be a single strand or a bundle of multiple strands used as a single conductor.

[0024] The finished coil is wound on a magnetic core or wound in an air core.

[0025] The inventors discovered in their experiments that the absolute value of the magnetic flux of the core of a cored inductor or the inner hole of an air-core inductor is negatively correlated with the inductance value. That is, for the same coil, the larger the absolute value of the magnetic flux of its core or inner hole, the smaller the inductance value. The change in inductance value is a function of the change in the absolute value of the magnetic flux of its core.

[0026] If a coil is wound in three or more layers, or if three or more coils are stacked together, the layers of the coil form a capacitive structure. When current flows through a coil with three or more layers, there will inevitably be a voltage difference between the layers, increasing the parasitic capacitance. When current flows through a coil with three or more layers, there will inevitably be a time difference in the current between the layers. The magnetic flux of each layer's core will change with the current, further causing the inductance of each layer to change synchronously. If each layer of the coil is powered separately, the series-connected layers will exhibit many characteristics due to the combination of voltage changes, current changes, interlayer parasitic capacitance, changes in magnetic flux causing synchronous changes in inductance, changes in self-resonant frequency, changes in mutual inductance, etc. Based on these physical characteristics, many functional applications of inductor elements can be designed.

[0027] The inventors applied this physical discovery to generators. By adjusting the magnetic flux of the generator stator poles, the inductance of the coils can be precisely adjusted. By adjusting the magnetic flux of the generator stator poles, the coil time constant, voltage and current phase, inductive reactance, stored energy, current flow, self-resonance and LC resonance, mutual inductance coupling coefficient, etc., can be adjusted. Based on the 90° phase difference between the voltage and current of the inductor and capacitor, the phase change of the voltage and current can be further adjusted, thereby changing the magnetic reluctance of the magnetic poles to the rotor rotation.

[0028] A low reluctance generator coil winding is formed by winding a coil with three or more layers using a self-resonant coil winding method to form a self-resonant coil; the self-resonant coil is installed or directly wound on the generator, and connected in series, parallel or a combination of series and parallel to form the low reluctance generator coil winding.

[0029] Because the magnetic flux of the electromagnet or permanent magnet in the generator rotor has a gradient distribution, the voltage of each turn of the stator coil also has a gradient distribution due to its distance from the rotor poles when the rotor rotates. When three or more layers of coils are used in a generator, the gradient distribution of magnetic flux to the rotor poles leads to a gradient distribution of voltage across the coil layers, increasing parasitic capacitance and causing inconsistencies in current flow time and quantity between layers. Since the coil layers share the same magnetic core, they form a transformer structure. The current flow in each layer generates mutual inductance, transferring energy to other layers through the core, thus creating self-resonance and LC resonance. The yoke, teeth, and pole shoes of the generator stator connect the magnetic circuits of adjacent poles, forming a transformer structure with magnetic gaps between the poles. Pole self-resonance can cause coupling resonance between adjacent poles, enabling mutual induction and energy transfer, and also causing resonance between the electromagnetic fields of the poles and the rotor poles. Current flows through each layer of the coil, and the magnetic core generates changes in magnetic flux due to the current flow. In turn, this affects the inductance, inductance time constant, inductive reactance, inductance stored energy, voltage and current, self-resonance and mutual inductance coupling resonance, LC resonance, etc. Resonance causes the magnetic poles to form magnetoelectric energy standing waves.

[0030] In AC circuits, the current of an inductor lags the voltage by 90°, while the current of a capacitor leads the voltage by 90°. Both inductors and capacitors have a time constant τ during charging and discharging; the inductor's time constant is related to its inductance value, and the capacitor's time constant is related to its capacitance value. The voltage and current changes during the first τ of charging and discharging differ between inductors and capacitors. When an inductor is charging, after 1τ, the current reaches approximately 63.2% of the power supply current; when it is discharging, after 1τ, the current drops to approximately 36.8% of the initial current. Similarly, when a capacitor is charging, after 1τ, the voltage reaches approximately 63.2% of the power supply voltage; when it is discharging, after 1τ, the voltage drops to approximately 36.8% of the initial voltage. Utilizing these characteristics of inductors and capacitors, by winding the stator coils into three or more layers, or by installing three or more layers of coils, and by applying the principle that the inductance value changes synchronously with the magnetic flux of the core, the phase shift angle of the voltage and current at the stator poles can be designed, thereby generating magnetoelectric energy standing waves at the generator stator poles. The electromagnetic fields generated by the superposition of voltage and current phase shifts and magnetoelectricity can also resonate with the rotor magnetic poles, causing the rotor to rotate under low magnetic resistance, and even forming a generator rotor that can generate electricity and drive motors, thereby improving the efficiency of the generator's mechanical energy to electrical energy conversion.

[0031] Breakthroughs in fundamental research have made it possible to significantly improve the efficiency of generators in converting mechanical energy into electrical energy. The inventors have creatively applied their original research findings, integrating inductor and capacitor manufacturing technologies with circuit design techniques into generator design and manufacturing. Based on these breakthroughs in fundamental principles, this technological achievement is now publicly disclosed.

[0032] Example 1:

[0033] The present invention relates to the application of a coil winding with three layers of reciprocating spiral coils in the same direction in a small permanent magnet magnetic field potential energy extraction generator.

[0034] The principle of the small generator designed and manufactured is as follows: the rotor is a 10-pole permanent magnet with N and S poles arranged alternately, the stator has 10 poles, and the yoke of the stator is fitted with 10 permanent magnets with the N pole pointing towards the axis. The direction of the stator poles and rotor poles is deflected radially from the axis by a certain angle.

[0035] Applying the self-resonant coil winding method described in this invention, the starting point of the wire is fixed at the intersection of the stator teeth and yoke. The wire is wound clockwise 7 turns towards the pole piece, fitting against the teeth, and then clockwise 7 turns towards the yoke. This process is repeated 11 times, resulting in a total of 77 turns, forming the first layer of the coil. The wire is then shifted 7 wire diameters to a fixed position, and the first layer of the coil is wound counterclockwise 7 turns towards the yoke, fitting against the yoke. This process is repeated 7 times counterclockwise, resulting in a total of 11 layers, resulting in a total of 77 turns. The wire is attached to the first layer of the coil, with its tail connected to the tail of the first layer of winding, forming the second layer of the coil. The head of the second layer of wire is connected to the head of the third layer of wire, and wound clockwise 7 turns towards the pole shoe while still attached to the magnetic pole, then wound clockwise 7 turns towards the yoke, attaching to the second layer of the coil. This process is repeated 11 times, resulting in a total of 77 turns, forming a coil with 3 layers and 231 turns. When current flows through the coil, the magnetic field direction of each winding layer is the same, as determined by the right-hand screw rule, as shown in the diagram. Figure 1 Adjacent coils are wound in the same way but in opposite directions, with the winding directions of the 10 magnetic poles alternating between clockwise and counterclockwise. The 5 clockwise coils and the 5 counterclockwise coils are connected in series, and then connected in parallel to form the generator's low reluctance coil winding, which is connected to the junction box and then to the rectifier module to output DC power.

[0036] Actual test results show the efficiency of the generator's mechanical energy to electrical energy conversion: at 600 rpm, with a power output of less than 50 watts, the efficiency of mechanical energy to electrical energy conversion is greater than 95%; at 1000 rpm, with a power output of less than 150 watts, the efficiency of mechanical energy to electrical energy conversion is greater than 90%.

[0037] The principle mechanism of the generator manufactured using this invention has an efficiency of converting mechanical energy into electrical energy greater than 95%, representing a significant improvement in efficiency. This method can improve upon traditional generators that use helical reciprocating coils.

[0038] Example 2:

[0039] This invention relates to an application embodiment of a coil winding with three layers of coils wound in the same direction. This invention improves traditional power generation. The improvement method for traditional bundled-wound generators is as follows:

[0040] Taking a 210-turn bundled winding as an example: First, 80 turns are bundled and tied together. Then, 70 turns are wound and tied together, followed by 60 turns and tied together. When installing into the wire slot, first, 80 turns are installed at the bottom of the slot, pressed with a mold, and fixed using methods such as injecting thermally conductive adhesive or slot wedges to form the first layer of the coil. Then, 70 turns are installed, pressed with a mold, and fixed using methods such as injecting thermally conductive adhesive or slot wedges to form the second layer of the coil. Then, 60 turns are installed and fixed with slot wedges to form the third layer of the coil. The layers of the coil are connected in series and stacked into a whole. When current flows through the coil, the magnetic field direction of each winding layer is the same, as determined by the right-hand screw rule. The contact surfaces between the coil winding layers are concentric and approximately equidistant from the radial surface of the rotor. The current direction of each coil is determined according to the design of the stator and rotor, and they are connected in series, parallel, or a combination of series and parallel to form a low-resistivity coil winding, which is then connected to the junction box to output electrical energy.

[0041] After the traditional generator is improved, compared with the traditional winding method, the shaft power consumption of the generator is reduced by more than 10% under the same power load. However, the modified generator has a large amount of harmonic voltage and current, which needs to be connected to the rectifier module to output DC power.

[0042] The present invention has been described in detail above. The above description is only a preferred embodiment of the present invention and should not be construed as limiting the scope of the present invention. All equivalent changes and modifications made in accordance with the scope of this application should still fall within the scope of the present invention.

Claims

1. A method for winding a self-resonant coil, characterized in that, The method is a unidirectional multilayer winding method, specifically: Fix the wire at the starting point, bundle or spirally reciprocate N turns to form the first layer of the coil, then attach the first layer of the coil and bundle or spirally reciprocate M turns, superimpose on the first layer to form the second layer of the coil, then attach the second layer of the coil and bundle or spirally reciprocate X turns, superimpose on the second layer to form the third layer of the coil, and wind the fourth, fifth and so on up to the Yth layer in the same way; The layers of the finished coil are connected in series and stacked together. When current flows through the coil, the magnetic field direction of each winding layer is the same, as determined by the right-hand screw rule.

2. The self-resonant coil winding method according to claim 1, characterized in that, The same-direction stacked winding method uses clockwise or counterclockwise winding. After the layers of the finished coil are connected in series, the continuous winding direction of the conductor is consistent. When the current flows through the coil, the magnetic field direction of each winding layer is the same according to the right-hand screw rule.

3. The method for winding a self-resonant coil according to claim 1, characterized in that, The conductor can be a single strand or a bundle of multiple strands used as a single conductor.

4. The method for winding a self-resonant coil according to any one of claims 1-3, characterized in that, The finished coil is wound on a magnetic core or wound in an air core.

5. A low reluctance generator coil winding, characterized in that, The self-resonant coil is wound into a coil with three or more layers using the self-resonant coil winding method described in claims 1-3, forming a self-resonant coil; the self-resonant coil is installed on the generator or directly wound on the generator, and connected in series, parallel or a combination of series and parallel to form the low magnetic reluctance generator coil winding.

6. The low reluctance generator coil winding according to claim 5, characterized in that, Three or more coils wound using bundled winding or helical reciprocating winding methods are stacked into one unit. They are connected in series, layer by layer, and stacked in a way that the magnetic field direction of each winding layer is the same when current flows through the coil, as determined by the right-hand screw rule. The stacked coils are installed on the generator and connected in series, parallel, or a combination of series and parallel to form the low magnetic reluctance generator coil winding.

Images