Coil Assembly Structure for Precise Radial Armature Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing coil assemblies in rotating electrical machines often experience misalignment with the armature core in the radial direction, which can affect the machine's performance and efficiency.
Innovation Solution
A coil assembly design featuring strip members made from electrically insulating material, rolled and stacked in a radial direction, with conductive coils formed on these members, and alternating thick-walled and thin-walled portions to minimize misalignment. The armature core is made of soft magnetic material, and the coil assembly is positioned on the outer or inner radial surface, with magnets arranged to face the coil assembly in the radial direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional coil assembly structure is used, then the structure is simple and production cost is reduced, but misalignment with the armature core in the radial direction occurs
Solution Approach 1:
The strip member is designed with varying thickness along its width, creating thin-walled portions and thick-walled portions. The thick-walled portions serve as alignment reference surfaces that engage with corresponding surfaces of the armature core, ensuring precise radial alignment. This local variation in thickness provides the necessary alignment function without requiring the entire structure to be complex
Solution Approach 2:
The thick-walled portions are pre-formed as integral parts of the strip member during the insulation material forming process. These alignment reference surfaces are prepared in advance to match the armature core surfaces, ensuring that when the coil assembly is installed, the alignment is automatically achieved without requiring additional adjustment or complex positioning mechanisms
2Reliability
If the coil assembly is designed with alignment features, then misalignment is minimized, but the structure becomes more complex
Solution Approach 1:
Rather than making the entire strip member complex, only specific local regions are thickened to create alignment reference surfaces. The thin-walled portions maintain the original simple structure for electrical insulation, while the thick-walled portions provide the necessary mechanical alignment function. This localized approach improves reliability without significantly increasing overall structural complexity
Solution Approach 2:
The alignment function is merged into the insulation material itself by forming the thick-walled portions as integral parts of the strip member. This eliminates the need for separate alignment components or additional parts, achieving reliable alignment while keeping the structure relatively simple by combining multiple functions into a single component
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 design effectively minimizes misalignment of the coil assembly with the armature core, enhancing the rotational stability and torque output of the electrical machine while maintaining a compact size.
Implementation Method 1
an armature core which is made from a soft magnetic material into a hollow cylindrical shape
Data Source
AI summary
A coil assembly includes a plurality of strip members which are rolled or wound in a circumferential direction of the coil assembly. The strip members have at least portions overlapping each other in a radial direction of the coil assembly and stacked on one another in the radial direction of the coil assembly. The strip members have a plurality of coils disposed thereon. The coil assembly also has a thin-walled portion and thick-walled portions. The thin-walled portion is defined by a portion of the strip members and has a first thickness in the radial direction. The thick-walled portions are defined by portions of the strip members and have a second thickness in the radial direction which is greater than the first thickness. The thick-walled portions are arranged away from each other in the circumferential direction.