Alternating Coiling Procedure for Stator Conductors

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Solution Overview

Problem

In electrical rotating machines with an uneven number of conductors per groove, the classical coiling procedure results in over-thicknesses and significant space requirements due to uneven layers of turns between phase systems, leading to inefficient use of space and coiling leading-out wires.

Innovation Solution

A coiling procedure that alternates the direction of rotation for each turn, ensuring at least two changes of direction occur in different angular zones, allowing for even distribution of conductors and homogenous thickness of leading-out wires by staggering the start and stop of conductor installation based on electronic control positioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the classical coiling procedure is used with an uneven number of conductors per groove, then the coiling process is simple to implement, but it results in over-thicknesses and significant space requirements due to uneven layers of turns

Engineering Contradiction:

Improvecoiling process simplicityVSAvoidspace requirement

Core Design Contradiction:

Ease of manufactureVSVolume of stationary object

Solution Approach 1:

The patent applies inversion by changing the conventional coiling sequence. Instead of completing all turns in one direction, the method alternates the direction of rotation for each successive turn (first direction for turn 1, second direction for turn 2, and so on). This inverted approach to the coiling sequence redistributes the conductor layers evenly, eliminating the over-thickness problem that occurs with the classical single-direction method when an uneven number of conductors per groove is used.

Inventive Principle:

Principle #13The other way round (Inversion)

2Ease of manufacture

If the classical coiling procedure is used with an uneven number of conductors per groove, then the coiling process is straightforward, but it creates zones with different numbers of layers (3 layers in Z1, 5 layers in Z2)

Engineering Contradiction:

Improvecoiling process straightforwardnessVSAvoiduniformity of conductor distribution

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

By inverting the coiling direction for each successive turn, the patent achieves uniform conductor distribution. The alternation of rotation directions ensures that conductors are deposited symmetrically on both sides of the stator, creating zones with equal numbers of layers rather than the uneven 3-layer and 5-layer zones produced by the classical method.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent implements periodic action through the regular alternation of coiling directions. Each turn follows a periodic pattern: one turn in the first direction, the next turn in the second direction, repeating this cycle throughout the coiling process. This periodic inversion of direction ensures consistent and uniform conductor distribution across all zones.

Inventive Principle:

Principle #19Periodic action

3Manufacturing precision

If the coiling rotation is inverted to distribute turns evenly, then homogenous thickness of leading-out wires is achieved, but the coiling procedure becomes more complex

Engineering Contradiction:

Improvehomogeneity of leading-out wire thicknessVSAvoidcoiling procedure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent achieves homogenous leading-out wire thickness by inverting the coiling direction for each successive turn. This systematic alternation ensures that the conductor buildup is uniform across all zones, producing leading-out wires with consistent thickness. While this adds a directional change step, the overall complexity remains manageable through the regular, predictable pattern of alternation.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS11336140B2Coiling procedure for the stator of an electrical rotating machine, and corresponding coiled stator

Publication Date: 2022.05.17 VALEO EQUIP ELECTRIC MOTEUR

AI summary

The invention mainly concerns a coiling procedure of a stator for a multiphase electrical rotating machine: the said stator comprising grooves, each intended to take up an uneven number of conductors of a coil, the said coil comprising two systems, each comprising one group of conductors (C1-C3, C1′-C3′) respectively, the said procedure comprises stages of installation of the conductors (C1-C3, C1′-C3′) into the said grooves, repeated in order to form a coil comprising several turns (S1-S9) completed alternately according to a first direction of rotation (K1) and according to a second direction of rotation (K2) opposite the first direction of rotation, with the characteristic that at least two changes of direction of rotation (CH1-CH8) from one turn to the other are carried out in different angular zones.