Bobbin Groove Configuration for Rotary Electric Machine Circuit Simplification
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Solution Overview
Problem
Existing rotary electric machines face complexity in circuit patterns due to non-intersecting winding sections of coil wires, leading to increased size and complexity, reduced degree of freedom in wire connection patterns, and higher costs.
Innovation Solution
The use of bobbins with specific groove configurations on the terminal fixing portion allows winding starting and finishing sections of coil wires to intersect or not intersect, enabling simplified circuit patterns and reduced machine size by alternating the positions of winding end portions, thereby enhancing the degree of freedom in wire connection patterns and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the winding starting section and winding finishing section are arranged to not intersect, then the coil wire routing is simplified, but the circuit pattern complexity increases and the degree of freedom in wire connection patterns decreases
Solution Approach 1:
The patent utilizes the axial direction as an additional dimension to arrange the winding sections. By allowing the winding starting section and winding finishing section to intersect when viewed in the axial direction, the design transforms a two-dimensional planar arrangement problem into a three-dimensional spatial arrangement, thereby simplifying circuit patterns while maintaining manufacturing ease
Solution Approach 2:
The terminal fixing portion is divided into multiple grooves (first groove, second groove, third groove, fourth groove) that independently guide different sections of the coil wire. This segmentation allows precise control over the routing of winding starting and finishing sections, enabling them to intersect in the axial direction while maintaining organized circuit patterns
2Ease of manufacture
If the winding sections are arranged in a conventional non-intersecting manner, then the manufacturing process is simpler, but the rotary electric machine size increases
Solution Approach 1:
By utilizing the axial dimension for intersecting winding sections, the patent achieves more compact spatial arrangement of coil wires. This three-dimensional arrangement allows the rotary electric machine to achieve a smaller overall size while maintaining manufacturing simplicity through the groove-guided winding process
3Ease of manufacture
If the winding end portions are fixed in conventional positions, then the manufacturing process is straightforward, but the degree of freedom in wire connection patterns is reduced
Solution Approach 1:
The terminal fixing portion is segmented into multiple grooves (first groove for winding starting section, second groove for winding finishing section, third and fourth grooves for alternative arrangements). This segmentation provides multiple designated positions for winding end portions, enhancing the degree of freedom in wire connection patterns while maintaining a straightforward groove-guided manufacturing process
Solution Approach 2:
The patent provides flexibility in wire connection patterns by allowing different arrangement configurations (intersecting or non-intersecting winding sections) while maintaining a consistent groove-guided manufacturing approach. This enables adaptation to different design requirements without complicating the manufacturing process
Data Source
AI summary
A bobbin for electrically insulating the stator core from a coil wire to be wound around the bobbin includes: a coil winding portion around which the coil wire is to be wound; and a terminal fixing portion to which a winding starting end portion and a winding finishing end portion of the coil wire are to be fixed. The terminal fixing portion includes a first groove configured to guide a winding starting section extending from the winding starting end portion of the coil wire to a winding starting position of the coil winding portion and a second groove configured to guide a winding finishing section extending from a winding finishing position of the coil winding portion to the winding finishing end portion of the coil wire to intersect the winding starting section when seen in an axial direction.