Armature Coil End Crank Layout for Compact Electric Rotating Machines
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Solution Overview
Problem
Conventional electric rotating machines face challenges in downsizing their coil ends due to complex manufacturing processes and potential insulation failures, which complicate quality control and increase the risk of damage to lead wire films.
Innovation Solution
The design incorporates a ring-shaped armature iron core with teeth and a rotor featuring magnetic-field poles, utilizing rectangular-shaped armature-coil elements with inflection points in the oblique sides to facilitate a crank portion that displaces radially, simplifying manufacturing and reducing interference between coil ends.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If cranks are provided on the apex portions of coil ends to raise coil end density, then the electric rotating machine can be downsized, but the manufacturing process becomes complex requiring 3-dimensional molding
Solution Approach 1:
The coil end is divided into multiple coil end portions, each with its own crank portion. This segmentation allows each portion to be molded independently using conventional 2-dimensional molding techniques, avoiding the need for complex 3-dimensional molding while achieving the same space-saving effect through coordinated arrangement of multiple segments.
Solution Approach 2:
The invention transitions from 3-dimensional molding to 2-dimensional molding by arranging multiple coil end portions in a specific spatial pattern. The cranks are positioned at different locations and orientations, allowing them to be formed using simpler 2-dimensional molding processes while still achieving high coil end density through their collective arrangement.
2Volume of moving object
If cranks are provided in the oblique side of the armature coil, then the coil end density is increased, but the bending portions crowd and cause damage to the lead wire film
Solution Approach 1:
The coil end is divided into multiple separate coil end portions, each with its own crank portion positioned at a different location. This segmentation distributes the bending portions throughout the coil end structure rather than crowding them in one area, reducing the risk of film damage and insulation failure while maintaining high density.
Solution Approach 2:
The multiple coil end portions are arranged with asymmetric positioning and orientation of their respective cranks. This asymmetric arrangement optimizes the spatial distribution of bending portions, ensuring they do not crowd together and minimizing stress concentration on the lead wire film, thereby improving insulation reliability.
3Volume of moving object
If the coil end is downsized, then the electric rotating machine can be made smaller, but the control of products and securing of quality become difficult
Solution Approach 1:
The coil end is segmented into multiple portions that can be manufactured using conventional 2-dimensional molding techniques. This segmentation simplifies the manufacturing process for each individual portion, making it easier to control product quality and ensure consistency, while the overall small size is achieved through the coordinated arrangement of these standardized segments.
Solution Approach 2:
The invention changes the molding approach from 3-dimensional to 2-dimensional, which simplifies the manufacturing parameters and process control. This parameter change makes it easier to maintain manufacturing precision and secure product quality, while still achieving the downsized coil end through the strategic arrangement of multiple molded portions.
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 allows for a readily manufactured, downsized electric rotating machine with improved insulation and reduced risk of damage, enabling efficient production and enhanced performance.
Implementation Method 1
an armature coil mounted on the armature iron core... a rotor that has a magnetic-field pole and whose outer circumferential portion faces an inner circumference portion of the armature iron core through an air gap
Data Source
AI summary
In the electric rotating machine, a crank portion that is displaced in a radial direction of an armature iron core is provided in an apex portion of a coil end portion; a first oblique side that slants with respect to an axis-direction endface of the armature iron core connects a first coil conductor portion with the crank portion; a second oblique side that slants with respect to the axis-direction endface of the armature iron core connects a second coil conductor portion with the crank portion; at least one of the first oblique side and the second oblique side has an inflection point, before being connected with the crank portion, that functions as a base point of a bending portion that is bent toward a radially outside of the armature iron core.