Air Core Coil Motor Simplifies Configuration
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Solution Overview
Problem
The segment coil configuration in motors requires extensive man-hours for formation and welding, leading to a complex motor design and hindered miniaturization due to coil ends protruding in the axial direction.
Innovation Solution
A motor design featuring a yoke with magnetic pole parts arranged in a circumferential direction and air core coils, where connection ends from adjacent coils are electrically connected, simplifying the configuration and reducing manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a segment coil configuration is used, then the motor can be constructed with distributed winding, but the configuration becomes complicated and requires extensive man-hours for forming and welding
Solution Approach 1:
The motor is divided into multiple independent air core coils, each corresponding to a specific magnetic pole part. This segmentation allows each coil to be manufactured and assembled separately, reducing overall configuration complexity and manufacturing difficulty compared to traditional distributed winding segment coils.
Solution Approach 2:
The patent transitions from the conventional planar winding arrangement to a three-dimensional spatial arrangement where air core coils are positioned around magnetic pole parts in the circumferential direction. This dimensional change simplifies the winding structure and reduces manufacturing complexity.
2Productivity
If a segment coil configuration is used, then distributed winding can be achieved, but manufacturing time increases due to extensive forming and welding
Solution Approach 1:
Air core coils are pre-formed and prepared before assembly, allowing for standardized manufacturing processes. This preliminary preparation reduces on-site forming and welding time, significantly improving manufacturing efficiency and reducing total man-hours required.
Solution Approach 2:
The patent replaces traditional mechanical winding and welding processes with a simplified assembly approach where pre-formed air core coils are positioned and electrically connected. This substitution eliminates time-consuming forming and welding operations, boosting productivity.
3Volume of moving object
If traditional coil winding is used, then electrical connection can be achieved, but coil ends protrude in the axial direction hindering miniaturization
Solution Approach 1:
The patent arranges air core coils in the circumferential direction around magnetic pole parts, utilizing the radial and circumferential dimensions rather than extending in the axial direction. This dimensional reorganization eliminates coil end protrusion and enables motor miniaturization.
Solution Approach 2:
Air core coils are positioned nested around magnetic pole parts in a compact circumferential arrangement. This nesting configuration minimizes the axial length required for coil ends, reducing overall motor volume and enabling miniaturization.
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 configuration simplifies the motor design, reduces man-hours, and minimizes coil end protrusion, enabling motor miniaturization and lowering power consumption.
Implementation Method 1
a plurality of air core coils arranged in the circumferential direction... The plurality of magnetic pole parts are disposed inside any of the plurality of air core coils
Data Source
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AI summary
[Problem] A configuration of a motor (1) is simplified. [Solving method] The motor (1) includes a yoke (10) including a plurality of magnetic pole parts (20) arranged in a circumferential direction, and a plurality of air core coils (40, 50, 60) arranged in the circumferential direction. The plurality of magnetic pole parts (20) are disposed inside any of the plurality of air core coils (40, 50, 60) in the circumferential direction. Among the plurality of air core coils (40, 50, 60), connection end parts drawn from two adjacent air core coils (40, 50, 60) are electrically connected to each other.