Axial Gap Motor Twisted Coil Winding for Flux Loss Reduction
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Solution Overview
Problem
In axial gap motors, the increased loss due to linkage magnetic flux in the inner rectangular wire of the coil leads to inefficiencies and potential abnormalities such as breakage, particularly in the inner coil wire.
Innovation Solution
The coil wires are twisted together to form a wire body that is wound along the rotation axis, allowing for positional shifts in the circumferential direction, reducing losses and eliminating the need for a collective coating, thereby increasing the space factor and further reducing losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two rectangular wires are wound side by side in the radial direction of the coil, then the coil structure is formed, but loss due to linkage magnetic flux increases in the inner rectangular wire
Solution Approach 1:
The coil wire is divided into multiple strands (first rectangular wire and second rectangular wire) that are twisted together. This segmentation allows the inner wire to periodically exchange positions with the outer wire through twisting, reducing the concentration of linkage magnetic flux in a single inner wire position.
Solution Approach 2:
The coil structure transitions from a static arrangement where inner wires remain fixed to a dynamic arrangement where the twisting creates periodic position exchange between inner and outer wires. This dynamic configuration reduces the cumulative effect of linkage magnetic flux on any single wire segment.
2Loss of energy
If coil wires are twisted together to form a wire body, then losses from linkage magnetic flux are reduced, but the device complexity increases
Solution Approach 1:
Multiple rectangular coil wires are merged into a single wire body through twisting. This combining approach achieves the benefit of reduced linkage magnetic flux losses while presenting a unified structure that is easier to handle and install compared to managing separate wires.
3Reliability
If a collective coating is applied to cover all coil wires, then protection is provided, but the space factor decreases
Solution Approach 1:
The collective coating is extracted or removed from the coil structure. Instead of applying a coating that covers all wires, the invention relies on the twisted configuration itself to manage the wires efficiently, thereby maintaining a higher space factor while still providing adequate protection through the twisted structure's inherent characteristics.
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 minimizes losses in the coil portion by avoiding excessive linkage magnetic flux and potential abnormalities, enhancing efficiency and reducing the risk of coil wire breakage.
Implementation Method 1
The rotary electric machine includes a stator and a rotor. The stator includes a coil portion having coil wires. The rotor is configured to rotate about a rotation axis and faces the stator along the rotation axis.
Data Source
AI summary
A rotary electric machine is driven by a supply of electric power. The rotary electric machine includes a stator and a rotor. The stator includes a coil portion having coil wires. The rotor rotates about a rotation axis and faces the stator along the rotation axis. The coil portion includes a wire body that has a wire shape in which the coil wires are twisted together. The wire body has an outer peripheral surface formed by the coil wires, and is wound to be stacked along the rotation axis.