Rotating Electric Machine Coil End Downsizing via Segmented Turn Portions
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Solution Overview
Problem
The existing rotating electric machines with distributed winding coils have large coil ends due to the overlapping of semicircularly bent shift portions, which complicates manufacturing and increases size.
Innovation Solution
The rotating electric machine design features inner-layer-side and outer-layer-side turn portions with specific bent and oblique portions that are twisted and positioned to reduce overlap, allowing for a more compact coil end by using a manufacturing method that forms these portions without twisting the oblique portions, thereby minimizing axial length and enhancing assembly reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the shift portion is bent into a semicircular shape, then the coil structure is simplified, but the coil end size increases due to overlapping of bent portions
Solution Approach 1:
The turn portion is divided into multiple segments: a bent portion, an oblique portion, and a shift portion. This segmentation allows each part to perform its specific function independently - the bent portion provides structural support, the oblique portion reduces overlap, and the shift portion connects slots - thereby maintaining structural simplicity while reducing coil end size
Solution Approach 2:
The invention introduces an oblique portion that extends in both axial and radial directions, adding a dimensional component to the traditional bent-shift structure. This oblique configuration allows the shift portion to be positioned more efficiently, reducing axial overlap while maintaining electrical connectivity between slots
2Ease of manufacture
If the shift portion is bent into a semicircular shape, then manufacturing is simplified, but assembly reliability decreases due to large coil end overlap
Solution Approach 1:
By segmenting the turn portion into bent, oblique, and shift portions, the invention maintains manufacturing simplicity through standardized forming processes while improving assembly reliability. The oblique portion specifically addresses assembly reliability by reducing overlap and improving insulation clearance
3Productivity
If the shift portion is bent into a semicircular shape, then productivity is improved through simplified manufacturing, but cooling performance deteriorates due to reduced gaps between turn portions
Solution Approach 1:
The segmented structure with oblique portions creates natural gaps and spacing between adjacent turn portions, improving air flow paths for cooling while maintaining manufacturing efficiency through standardized forming processes
Solution Approach 2:
The oblique portion extends in both axial and radial directions, creating three-dimensional spacing that improves cooling air flow paths between turn portions while maintaining a compact overall structure
Data Source
AI summary
Provided is a rotating electric machine capable of downsizing a coil end. The rotating electric machine includes an armature core and a plurality of coils. The plurality of coils each include a plurality of turn portions. The plurality of turn portions each include an inner-layer-side turn portion and an outer-layer-side turn portion. The inner-layer-side turn portion includes a first inner-layer-side bent portion, a first inner-layer-side oblique portion, and an inner-layer-side shift portion which is twisted. The outer-layer-side turn portion includes a first outer-layer-side bent portion, a first outer-layer-side oblique portion, and an outer-layer-side shift portion. The outer-layer-side shift portion has the inner-layer-side shift portion arranged between the outer-layer-side shift portion and the armature core.