Additive Winding Head for Electric Rotating Machine
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Solution Overview
Problem
The existing end winding arrangements for electrical rotating machines result in significant axial space usage, ohmic losses, and increased complexity due to the need for cooling and stiffening, which affects efficiency and rotor dynamics, especially in high-speed machines, and are costly and labor-intensive to produce.
Innovation Solution
An end winding arrangement featuring a base body with an electrically conductive material coated with an insulating layer, where conductors are applied using additive manufacturing processes such as 3D printing or thermal spraying, allowing for complex and compact structures with improved insulation and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional bending and offsetting methods are used to create winding heads, then conductor geometry can be achieved, but axial space consumption increases significantly
Solution Approach 1:
The patent applies parameter changes by transitioning from mechanical bending and offsetting processes to additive manufacturing parameters. The winding head is built layer-by-layer with precise control over conductor placement, cross-sectional shape, and insulation integration, enabling complex geometries without the axial space penalty of traditional bending methods.
Solution Approach 2:
The invention moves from 2D planar conductor arrangements to 3D volumetric construction through additive manufacturing. Conductors are deposited in multiple layers with varying orientations, creating complex three-dimensional geometries that optimize space utilization and reduce axial length while maintaining required conductor patterns.
2Reliability
If traditional manual joining and insulation methods are used, then conductor connections can be made, but manufacturing complexity and labor intensity increase
Solution Approach 1:
The patent merges multiple separate manufacturing operations into a single additive manufacturing process. Conductor deposition, insulation application, and structural formation are integrated into one continuous build process, eliminating the need for separate joining and insulation steps while maintaining connection reliability through controlled layer adhesion.
Solution Approach 2:
The invention replaces manual mechanical joining operations with automated additive manufacturing processes. Conductors are joined through controlled material deposition and layer bonding rather than mechanical fastening or soldering, reducing labor intensity and process complexity while ensuring consistent connection quality.
3Reliability
If conventional winding head designs are used, then electrical connection can be established, but ohmic losses increase due to longer conductor paths
Solution Approach 1:
The patent applies preliminary action by pre-optimizing the conductor path geometry during the additive manufacturing planning stage. The winding head structure is designed with minimal conductor lengths and direct current paths from the outset, preventing ohmic losses rather than addressing them afterward, while ensuring reliable electrical connections through precise conductor placement.
4Stability of the object's composition
If traditional stiffening measures are applied to prevent vibrations, then mechanical stability can be achieved, but additional space and weight are required
Solution Approach 1:
The patent employs composite materials by integrating reinforcement elements directly into the additive manufactured winding head structure. Different materials with varying mechanical properties are deposited in specific patterns to provide stiffness and vibration resistance where needed, while maintaining overall structure minimization and reducing weight compared to traditional uniform stiffening approaches.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces the axial length, minimizes ohmic losses, enhances mechanical stability, and simplifies production, making the end winding arrangement more efficient and cost-effective compared to traditional methods.
Implementation Method 1
the base body comprises an electrically conductive material with an electrically insulating coating, wherein the conductors are connected to the base body via the electrically insulating coating
Implementation Method 2
the conductors are applied to the electrically insulating coating by means of a first additive manufacturing process
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a winding head arrangement (4) for an electric rotating machine. According to the invention, to provide a winding head arrangement (24) which is simpler and more cost-effective to produce compared with the prior art, the winding head arrangement (24) has at least one main body (26, 28) and a plurality of conductors (30) made of a first metal material, wherein the main body (26, 28) comprises an electrically conductive material having an electrically insulating coating (35), the conductors (30) are connected to the main body (26, 28) via the electrically insulating coating (35) and the conductors (30) are applied to the electrically insulating coating (35) by means of a first additive manufacturing method.