Armature Coil Convex-Concave Shaping for Space Factor
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Solution Overview
Problem
Conventional armature coils for rotary electric machines have a limited space factor, which restricts the output of these machines, and existing manufacturing methods do not adequately address the need for further improvement in this area.
Innovation Solution
The armature coil design features a trapezoidal shape with narrower circumferential width towards the radially inner side, where one coil conductor is formed in a convex shape and another in a concave shape, and a method involving metal dies to shape the coil conductors to match the slot shape, enhancing the space factor by increasing the joining degree between conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional rectangular or trapezoidal coil conductors are used with parallel planes, then the manufacturing process is simple, but the space factor is limited and cannot be further improved
Solution Approach 1:
The coil conductor cross-section is designed with asymmetric convex and concave portions, where one coil conductor has a convex shape and another has a corresponding concave shape. This asymmetric design allows the conductors to interlock and fit more tightly within the slot, improving the space factor while maintaining manufacturability through standard pressing processes.
Solution Approach 2:
The coil conductor is designed with localized convex and concave portions at specific regions rather than uniform shaping throughout. This local quality approach allows targeted optimization of the fitting between conductors in the slot, improving space utilization without complicating the overall manufacturing process.
2Quantity of substance
If coil conductors are deformed to match the slot shape, then the space factor is improved, but the manufacturing complexity increases
Solution Approach 1:
The convex and concave shapes are formed in the coil conductors during the preliminary pressing operation using a pressing die with the corresponding groove pattern. This preliminary action integrates the shaping process into the standard coil manufacturing flow, avoiding additional complex deformation steps after the conductors are assembled in the slot.
3Ease of manufacture
If the circumferential width of coil conductors is uniform, then the manufacturing process is straightforward, but the packing efficiency in the slot is suboptimal
Solution Approach 1:
The coil conductors feature asymmetric convex and concave portions that create a more efficient packing arrangement within the slot. The convex portion of one conductor fits into the concave portion of another, reducing gaps and improving packing efficiency while maintaining a relatively simple manufacturing process using standard pressing techniques.
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 design significantly improves the space factor, leading to a higher output rotary electric machine by enhancing the contact properties and packing efficiency of the coil conductors within the slots.
Implementation Method 1
pressing the coil conductors arranged in the groove of the lower metal die by an upper metal die having a rod-shaped end portion slightly narrower than the width of the groove; forming more flattened toward the coil conductor arranged at the end of the groove by being pressed to a predetermined position by the rod-shaped end portion of the upper metal die
Data Source
AI summary
A method of manufacturing an armature coil includes steps of arranging a plurality of coil conductors of the armature coil between an end metal die and a back portion metal die on a lower metal die; pressing, with the upper metal die in a pressing direction, the plurality of the coil conductors arranged between the end metal die and the back portion metal die on the lower metal die; and removing coil conductors that become formed in a convex shape and a concave shape from the lower metal die. The upper metal die may be provided with an inclined portion on a lower metal die side of the upper metal die, and the upper metal die may be configured to be pressed such that a space is formed by the dies, the space having a width that gets gradually narrower.