Brushless Motor Windings Rectangular Segments
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Solution Overview
Problem
Conventional brushless electric motor windings are inefficiently packed, leading to low electrical and thermal conductivity, hot spots, and reduced power and reliability due to air gaps and imperfections in coiled wires, which complicates the motor design and fabrication.
Innovation Solution
The windings are assembled in an 'n' or 'u' shape pattern around stator teeth or a central axis, stacked and offset to form solenoids, eliminating air gaps and allowing for efficient packing, and connected to dedicated phase wires, enabling the windings to be cut from thin metal sheets or formed via additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If coiled wires with circular or hexagonal cross section are used to form windings, then the windings can be easily manufactured, but the electrical conductivity and thermal conductivity are reduced due to air gaps between wires
Solution Approach 1:
The patent changes the cross-sectional shape parameter of the wires from circular or hexagonal to rectangular with aspect ratios between 2:1 and 10:1. This parameter change allows the wires to pack together without air gaps while maintaining ease of manufacture through standard winding processes.
Solution Approach 2:
The patent uses rectangular wires that can be stacked in multiple layers with different orientations (0 degrees, 60 degrees, 120 degrees) to create a composite winding structure. This composite arrangement eliminates air gaps and improves both electrical and thermal conductivity while maintaining manufacturability.
2Ease of manufacture
If coiled wires are used to form windings, then the windings can be manufactured using standard processes, but hot spots and electrical shorts occur due to stretches, twists, and kinks from coiling
Solution Approach 1:
The patent segments the winding structure into multiple discrete rectangular wire segments that are stacked together. Each segment maintains its rectangular cross-section and can be independently positioned, eliminating the continuous coiling process that causes stretches, twists, and kinks.
Solution Approach 2:
The patent transitions from a three-dimensional coiled structure to a multi-layer stacked structure where rectangular wires are arranged in discrete layers at specific angles (0°, 60°, 120°). This dimensional reorganization eliminates the mechanical stress and deformation associated with coiling while maintaining the winding's electromagnetic function.
3Ease of manufacture
If circular wires are used for windings, then the wires are easy to manufacture and handle, but they pack together inefficiently with large air gaps reducing conductivity
Solution Approach 1:
The patent changes the cross-sectional geometry parameter from circular to rectangular with high aspect ratios (2:1 to 10:1). This parameter change enables efficient packing arrangements where multiple rectangular wires can be stacked tightly together without air gaps, significantly increasing the quantity of conductive material per unit volume.
4Quantity of substance
If hexagonal wires are used for windings, then the wire packing efficiency is improved compared to circular wires, but twists and kinks form during coiling causing hot spots
Solution Approach 1:
The patent segments the winding into discrete rectangular wire segments that are stacked in controlled layers. This segmentation eliminates the continuous coiling process that causes twists and kinks in hexagonal wires, while maintaining efficient packing through the rectangular geometry that allows tight stacking arrangements.
Data Source
AI summary
Methods of assembling motor windings comprising wrapping windings around a central longitudinal axis in a cylindrical shape having a plurality of annularly spaced positions such that the windings form “n” and/or “u” shapes around the positions. As the windings encircle the longitudinal axis, they are wrapped in an outward spiral or inward spiral such that each pass of the windings is stacked on a previous pass.