Auxiliary Winding Tool for Electric Machine Stator
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Solution Overview
Problem
Existing methods for winding electric machines with distributed windings require large end disks, leading to bulky machines unsuitable for compact installations and result in uneven power density due to varying wire lengths across phases.
Innovation Solution
A method using a reversible auxiliary winding tool with a clamping mechanism featuring rotatable inner parts with oblique grooves, which absorbs winding forces and guides wires into the stator or rotor, allowing for dense and even windings with compact end windings, and is removed after the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If end disks are used for distributed windings, then the winding structure is stable and easy to manufacture, but the machine size increases and installation space is reduced
Solution Approach 1:
The patent removes the end disks from the winding structure, extracting the problematic component that caused increased machine size. The wire layers are held in position by the clamping mechanism integrated into the stator core, eliminating the need for separate end disk components.
Solution Approach 2:
The patent introduces a clamping mechanism with clamping teeth as an intermediary element that performs the function previously provided by end disks. This clamping mechanism secures the wire layers at the slot openings without requiring the bulky end disk structure.
2Ease of manufacture
If end plates are used to secure wire layers, then the winding process is simplified, but wire length variations across phases increase power density unevenness
Solution Approach 1:
The clamping teeth are positioned at specific slot openings where needed, providing localized clamping action. This allows precise control over wire layer positioning at critical locations without affecting the overall wire length uniformity across different phases.
Solution Approach 2:
The clamping mechanism can be dynamically adjusted during the winding process, allowing the clamping force and position to be optimized for each phase independently, thereby maintaining wire length uniformity while simplifying the winding process.
3Strength
If a fixed auxiliary winding tool is used, then the tool can withstand winding forces, but the tool cannot be removed after winding
Solution Approach 1:
The auxiliary winding tool transitions from a fixed state during winding to a removable state after winding. The tool is firmly secured during the winding process to withstand forces, then can be easily removed after winding is complete, providing dynamic adaptability to different operational phases.
Solution Approach 2:
The auxiliary winding tool is temporarily installed for the winding operation, performs its function during the winding phase, and is then removed. This periodic installation and removal cycle allows the tool to provide strength when needed without permanently increasing machine complexity.
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
Enables precise and compact winding of electric machines with improved power density by absorbing winding forces and guiding wires efficiently, reducing installation space requirements and minimizing wire length discrepancies across phases.
Implementation Method 1
the clamping mechanism comprises at least one rotatable inner part with oblique grooves on which bolts of respective clamping teeth slide, so that a rotation of the at least one inner part causes a radial movement of the respective clamping teeth via the bolts
Data Source
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AI summary
The invention relates to a method for winding a number of wire receptacles of stator and/or rotor of an electric machine with a number of wire layers, in which method the wire layers are applied by means of at least one auxiliary winding tool, which is reversibly arranged on the wire receptacles, for absorbing the winding force and for guiding the wire into the stator and/or the rotor, and wherein the at least one auxiliary winding tool is secured, for the purpose of winding, by means of a clamping mechanism which is surrounded by the stator and/or the rotor, and after the winding the at least one auxiliary winding tool is removed from the electric machine by releasing the clamping mechanism. In addition, the present invention relates to an auxiliary winding tool and to an electric machine.