Armature Winding Guide for PMDC Motors
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Solution Overview
Problem
In small PMDC motors, the winding process leads to uneven wire distribution and resistance, causing imbalance and vibration due to windings being wound on top of each other, especially in high fill rate and fine wire applications, which affects motor performance and requires material removal for balancing.
Innovation Solution
The use of radially extending vanes or fingers within the winding tunnels, formed by the laminations, to separate windings and maintain even spacing, ensuring consistent wire distribution and preventing larger windings from being wound on top of smaller ones, thus maintaining balance and reducing vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If windings are wound in high fill rate applications without separation structures, then the winding tunnel space is efficiently utilized, but the windings overlap and create uneven distribution and resistance
Solution Approach 1:
The winding tunnel is segmented into separate sections using radially extending vanes or fingers formed by the laminations. These vanes divide the common winding tunnel into distinct zones for adjacent windings, preventing overlap while maintaining high fill rate. Each vane creates a physical barrier that segments the space, ensuring uniform wire distribution without reducing the overall wire quantity.
2Ease of manufacture
If windings are wound without separation guides, then the manufacturing process is simpler, but the windings become uneven in size and resistance
Solution Approach 1:
The separation vanes are pre-formed as integral parts of the laminations before the winding process begins. This preliminary action of creating separation structures in advance allows the winding machine to operate without complex guidance mechanisms, maintaining process simplicity while ensuring consistent winding placement and uniformity throughout production.
3Stability of the object's composition
If the armature core is balanced before winding, then the initial balance is good, but the final armature becomes out of balance after winding due to uneven wire distribution
Solution Approach 1:
The separation vanes are installed in advance on the armature core before winding begins. This preliminary structural preparation ensures that as windings are added, the wire distribution remains uniform and the center of mass remains consistent, preserving the armature's balance throughout the winding process without requiring post-winding material removal.
4Stability of the object's composition
If automated balancing machines remove material to balance the armature, then the balance is improved, but the performance deteriorates due to material removal
Solution Approach 1:
The separation vanes prevent the harmful condition of uneven winding distribution before it occurs during the winding process. By maintaining uniform wire distribution from the start, the need for automated balancing machines is eliminated, preserving the armature's integrity and motor performance without requiring material removal that would compromise reliability.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A small PMDC motor has a wound salient pole armature. The armature 22 has a winding guide 38 disposed within each winding tunnel 36 formed between adjacent salient poles of the armature. The winding guide 38 is arranged to separate the radially inner portion of the respective winding tunnel whereby windings 30 wound about the adjacent salient poles of the armature are restrained from entering into the opposite radially inner portion of the winding tunnel 36.