Angled Sub-Conductor Winding Heads for Electric Machines
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Solution Overview
Problem
Classically manufactured end windings in electrical machines result in a minimum height that cannot be undershot due to geometric factors, leading to increased installation space, higher material costs, and power losses due to larger resistances, limiting their use in applications with limited space and reducing efficiency.
Innovation Solution
A component for electrical machines featuring a magnetically conductive core with radially angled sub-conductors that are inserted into grooves and connected to form windings, reducing the axial length by bending the conductor sections into a flat end winding shape, allowing for a smaller installation space and reduced material usage while maintaining performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If classically manufactured end windings are used, then the winding overhang height is determined by geometric factors, but this results in increased installation space requirements and higher material costs
Solution Approach 1:
The patent applies dimensionality change by transitioning the winding overhang from a predominantly axial extension to a radially oriented configuration. The conductor sections are angled radially outward from the core, changing the spatial dimension in which the winding overhang extends. This allows the same functional length to be achieved with reduced axial projection, thereby reducing installation space requirements while maintaining the necessary electrical path length.
Solution Approach 2:
The patent changes the geometric parameters of the winding overhang by introducing a radial angle component. Instead of the traditional axial alignment, the conductor sections are positioned at radial angles, fundamentally changing the spatial parameters. This parameter change enables the winding overhang to achieve its required length through radial extension rather than axial extension, resolving the contradiction between length requirements and space constraints.
2Length of stationary object
If classically manufactured end windings are used, then the winding overhang height is determined by geometric factors, but this leads to greater material costs due to increased length
Solution Approach 1:
By reorienting the winding overhang from axial to radial dimensions, the patent reduces the total conductor length required to achieve the same functional performance. The radial configuration allows for more direct current paths and eliminates unnecessary axial extensions, thereby reducing material consumption and associated costs while maintaining the required electrical characteristics.
Solution Approach 2:
The patent optimizes material usage by changing the geometric parameters of the winding layout. The radial angulation of conductor sections creates a more efficient spatial arrangement that reduces the total conductor length needed compared to classical axial configurations. This parameter optimization directly reduces material costs while preserving the necessary winding overhang functionality.
3Length of stationary object
If classically manufactured end windings are used, then the winding overhang height is determined by geometric factors, but this results in power losses due to larger resistances
Solution Approach 1:
The radial orientation of the winding overhang sections shortens the effective current path length compared to axial configurations. By changing the spatial dimension from axial to radial, the patent reduces the resistance encountered by current flow, thereby minimizing I²R power losses while maintaining the necessary winding geometry for electromagnetic function.
Solution Approach 2:
The patent reduces power losses by optimizing the geometric parameters of the winding layout. The radial angulation creates shorter and more direct current paths, reducing the total resistance of the winding overhang. This parameter optimization directly addresses energy efficiency by minimizing resistive losses while preserving the functional requirements of the winding structure.
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 approach enables the creation of electrical machines with reduced axial length, lower costs, and higher power density, achieving the same performance with a smaller size and less material, thereby improving efficiency and reducing power losses.
Implementation Method 1
a plurality of sub-conductors running in the axial direction in the openings in order to generate a magnetic field in the magnetically conductive core when energized
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a component (12) for an electric machine (10), comprising a magnetically conductive core (16) having a plurality of openings (18), which extend along an axial direction of the core (16), and a plurality of sub-conductors (20), which extend into the openings (18) in the axial direction, in order to generate a magnetic field in the magnetically conductive core (16) when energized; wherein the sub-conductors (20) are inserted into the openings (18) and ends (32) of the sub-conductors (20) have been connected to each other. Sections (22) of the sub-conductors (20) which have ends connected to each other and that protrude out of a face (26) of the magnetically conductive core (16) are angled to form a winding head (38) in a radial direction.