Rotary Machine Coil With Compound Outer Surface
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Solution Overview
Problem
Switched reluctance motors face inefficiencies at both low speeds with high current and higher speeds with lower current due to coil design limitations, where coils either overheat or fail to perform efficiently as operating frequencies increase.
Innovation Solution
A coil design for rotary electric machines featuring a plurality of electrically conductive wires wrapped around a stator pole with a compound outer surface, including angled leg sections and a bonding material to reduce voids and enhance copper fill, allowing for lateral movement of wires during assembly to improve electrical performance and thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If coils are designed with traditional wire configurations, then electrical performance may be adequate, but the coils cannot carry significant current without excessive heating
Solution Approach 1:
The patent changes the physical parameters of the coil by using a braided wire configuration instead of traditional stranded wire, and by impregnating with bonding material under vacuum. This transforms the coil from a loose wire assembly to a dense, solid-like structure with improved thermal and electrical properties
Solution Approach 2:
The patent creates a composite structure by combining multiple copper wires into a braided configuration and then impregnating with a bonding material (such as epoxy or polymer). This composite approach maintains the electrical conductivity of copper while adding structural integrity and thermal management capabilities
2Quantity of substance
If coils have increased current carrying capacity, then they can handle higher currents, but they do not perform efficiently as operating frequencies increase
Solution Approach 1:
The patent modifies the coil's physical parameters by changing from traditional wire winding to a braided configuration with vacuum impregnation. This creates a denser structure with reduced air gaps, improving both current carrying capacity and high-frequency performance by reducing skin effect and proximity effect losses
Solution Approach 2:
The patent converts the typically harmful air gaps and voids between wires into a beneficial structure by impregnating with bonding material. This eliminates the harmful effects of air gaps (poor thermal contact, increased resistance) while maintaining electrical conductivity and improving high-frequency performance
3Ease of manufacture
If coils are manufactured with traditional methods, then production is straightforward, but air gaps and voids reduce electrical efficiency
Solution Approach 1:
The patent performs preliminary actions during the manufacturing process by first forming the braided wire configuration, then applying bonding material, and finally using vacuum impregnation to eliminate air gaps before the coil is installed. This preliminary elimination of voids ensures maximum electrical efficiency is achieved during manufacturing itself
Solution Approach 2:
The bonding material acts as an intermediary substance that fills the air gaps between wires during manufacturing. This intermediary material improves electrical contact and thermal conductivity while eliminating the harmful effects of air gaps, and the vacuum process serves as an intermediary mechanism to ensure complete impregnation
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
The design enhances electrical efficiency, reduces copper losses, and simplifies the manufacturing process by minimizing air gaps and skin effects, while improving thermal conductivity and reducing susceptibility to partial discharge failures.
Implementation Method 1
improving thermal conductivity
Implementation Method 2
minimizing air gaps and skin effects
Data Source
AI summary
A coil for a rotary electric machine includes a plurality of electrically conductive wires defining a group of wires wrapped to define a plurality of turns. The coil further includes a pair of major sections and a compound outer surface along the pair of major sections. The compound outer surface has a first leg section and a second leg section with the first leg section and the second leg section at an angle to each other. A bonding material is positioned along portions of the pair of major sections to define the compound outer surface.