Cylindrical Coil Body with Arc Junctions for High Current
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Solution Overview
Problem
Existing coreless rotating electrical machines require a coil body design that is both space-saving and capable of handling large currents, while maintaining a cylindrical shape with sequentially arranged U-phase, V-phase, and W-phase coil portions for efficient electrical connection.
Innovation Solution
A cylindrical coil body design with conductive junctions connecting U-phase, V-phase, and W-phase coil portions in a circumferential direction, featuring arc-shaped junctions with varying radii and electrical insulation, allowing for compact and miniaturized construction while enabling high current passage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the coil body is miniaturized and space-saving, then the volume and size are reduced, but the current carrying capacity may be compromised
Solution Approach 1:
The coil body is divided into multiple coil portions (first, second, third, and fourth coil portions) arranged circumferentially, with each portion contributing to the overall current carrying capacity. This segmentation allows the current to be distributed across multiple paths, maintaining high current capacity while reducing the volume of each individual coil section.
Solution Approach 2:
The coil portions are arranged in the circumferential direction around the cylindrical axis, utilizing the third dimension (circumferential arrangement) to increase the effective current carrying area without significantly increasing the radial or axial dimensions. This dimensional arrangement allows multiple coil portions to be packed efficiently in a compact cylindrical volume.
2Productivity
If multiple phases are sequentially arranged in the circumferential direction, then the electrical connection efficiency is improved, but the structural complexity increases
Solution Approach 1:
Adjacent coil portions of the same phase are electrically connected through conductive connections, merging their electrical functions. For example, the first and second coil portions are connected to form a complete U-phase coil, while the third and fourth coil portions form a V-phase coil. This merging simplifies the electrical connection structure by reducing the number of separate connection points while maintaining efficient current flow across all phases.
Solution Approach 2:
Different regions of the coil body have specialized structures optimized for their specific functions. The coil portions have varying winding patterns and connection configurations tailored to their phase requirements, while the cylindrical support structure provides uniform mechanical support throughout. This local optimization allows efficient electrical connections without requiring complex structures throughout the entire device.
3Reliability
If the junction extends in the circumferential direction to form an arc shape, then the electrical connection is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The conductive junction is formed as an arc-shaped structure that conforms to the cylindrical geometry of the coil body. This curved configuration naturally follows the circumferential arrangement of the coil portions, providing reliable electrical contact points that adapt to the cylindrical form factor. The arc shape distributes mechanical stress evenly along the connection path, enhancing connection reliability while accommodating manufacturing tolerances through its geometric flexibility.
Data Source
AI summary
One U-phase coil portion and the next U-phase coil portion in a circumferential direction, one V-phase coil portion and the next V-phase coil portion in the circumferential direction, and one W-phase coil portion and the next W-phase coil portion in the circumferential direction are electrically connected by conductive junctions, respectively.