Armature Winding Balance Correction via Variable Wire Diameter
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Solution Overview
Problem
Conventional armatures in rotating electrical devices face challenges in maintaining weight balance in the circumferential direction, leading to potential vibration and noise, which are often addressed by increasing the number of components or processes, thereby increasing costs.
Innovation Solution
The method involves forming plural types of winding coil sections with different winding wire diameters on a core member with a rotation shaft, using varying tensions of flyers to wind the wires, allowing for the same diameter wires to be used across different flyers, and incorporating a D-shaped cut in the rotation shaft to offset weight differences, thus correcting the weight balance without increasing the number of components or processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a balancing member is added to the armature or balance correction is performed after assembly, then the weight balance in the circumferential direction is corrected, but the number of components and processes increases, leading to increased costs
Solution Approach 1:
The patent applies local quality by varying the winding wire diameters in different circumferential positions of the armature. Specifically, winding coil sections at different angular positions use different wire diameters (e.g., larger diameter at some positions, smaller at others) to create localized weight differences that compensate for the D-shaped cut portion, achieving balance correction without adding components or processes
Solution Approach 2:
The patent changes the parameter of winding wire diameter in different circumferential positions to correct weight balance. By adjusting the wire diameter parameter locally in different slots, the armature achieves proper weight distribution without requiring additional balancing members or post-assembly correction processes
2Manufacturing precision
If different diameter winding wires are used for different winding coil sections, then the weight balance variation is corrected, but the manufacturing complexity increases
Solution Approach 1:
The patent segments the armature winding into multiple types of winding coil sections based on circumferential position. Each segment uses a specific wire diameter according to its position relative to the D-shaped cut portion, allowing systematic weight balance correction through structured segmentation of the winding process
Solution Approach 2:
The patent implements preliminary action by pre-planning and pre-assigning different wire diameters to different winding coil sections during the manufacturing process. The weight balance correction is built into the winding process itself through predetermined wire selection based on slot position, rather than requiring post-assembly adjustments
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 effectively corrects the weight balance in the circumferential direction of the armature, reducing costs and preventing vibration and noise, while maintaining a balanced design.
Implementation Method 1
causing the diameters of the winding wires respectively forming the plural types of winding coil sections to be different by differing tensions of the plural flyers to differ the amount of extension of the winding wires wound using the plural flyers
Data Source
AI summary
An armature manufacturing method includes preparing a core member that includes a rotation shaft at a central portion and that is formed with plural teeth in a radiating shape centered on the rotation shaft; and winding winding wires onto slots between the plural teeth so as to form plural types of winding coil sections, each with a different winding wire diameter.