Coil Former Tapered Block for Copper Packing Density
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Solution Overview
Problem
Conventional coil winding techniques face challenges in achieving high copper packing density without bulging at cross-over locations, leading to reduced thermal conductivity and increased complexity in winding processes, especially for ortho-cyclic coils.
Innovation Solution
A coil former with an angled inner radius and tapered block design allows for restricted cross-over locations, enabling maximum copper packing density around the winding circumference while maintaining a consistent width, and facilitating easier removal of the coil from the former.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional coil winding techniques are used to achieve high copper packing density, then the amount of copper in the winding area increases, but bulging occurs at cross-over locations
Solution Approach 1:
The patent applies preliminary action by pre-positioning the wire at specific locations on the drum before winding begins. The wire is placed in predetermined positions that guide it through the winding process, ensuring that cross-over points are controlled and do not cause bulging. This preliminary placement of the wire establishes the correct path and tension distribution before the winding force is applied.
Solution Approach 2:
The patent applies local quality by providing support structures at specific locations along the winding path, particularly at cross-over points. These support elements are positioned locally where needed to maintain uniform coil shape, rather than providing uniform support throughout. This localized intervention prevents bulging only where cross-overs occur, allowing high copper packing density elsewhere.
2Quantity of substance
If ortho-cyclic coil winding is used to achieve maximum copper packing, then copper density increases, but the winding process complexity increases
Solution Approach 1:
The patent introduces intermediary elements such as drums and support structures that mediate the winding process. These intermediaries simplify the complexity of ortho-cyclic winding by providing physical guidance for the wire path and maintaining proper tension distribution. The drum acts as an intermediary that converts complex multi-directional winding into a simpler rotational process while still achieving ortho-cyclic packing density.
Solution Approach 2:
The patent applies segmentation by dividing the winding process into discrete, manageable segments using multiple drums and support points. Rather than attempting to control the entire winding process as a single complex operation, the system breaks it down into separate functional zones: wire placement, tension application, and guided winding. This segmentation reduces overall process complexity while maintaining high copper packing density.
3Quantity of substance
If cross-over locations are restricted to a single area, then copper packing density improves, but thermal conductivity decreases
Solution Approach 1:
The patent applies parameter changes by carefully controlling the geometry and distribution of cross-over points. Rather than simply restricting cross-overs to a single area, the system optimizes the parameters of those cross-over locations including their position, angle, and spacing. This parametric optimization allows maintained copper packing density while minimizing the negative impact on thermal conductivity through proper geometric arrangement.
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 solution achieves high copper packing density without bulging, enhances thermal conductivity, and simplifies the winding process by ensuring all cross-over locations occur in a single area, improving the performance and ease of manufacturing of high-performance coils.
Implementation Method 1
The tapered block design creates friction-based mechanical constraint that guides the wire to cross over at specific locations, preventing random winding paths and enabling consistent coil geometry with maximum copper packing
Implementation Method 2
The angled inner radius distributes wire tension uniformly across the coil former surface, directing forces to prevent localized bulging and maintain consistent coil width throughout the winding process
Implementation Method 3
Copper has almost the highest thermal conductivity of any material, and thus, when turns of copper are placed close to one another, these turns can share the heat and also help to dissipate the heat to the stator material
Data Source
AI summary
A coil former provides for restricted cross-over locations for a coil resulting in an optimum wire packing at all points within the coil. The coil former has a first side wall in a spaced relation to an opposing second side wall, wherein a cavity formed between the side walls accommodates multiple turns of wire for forming a coil. A block is fixed between the opposing first and second side walls and has its peripheral wall surface tapered from the first wall surface inwardly toward the opposing second wall surface for preferentially receiving and positioning turns of wire forming the coil.