Electric Machine Coil Group Installation With 3D Coil Head Compaction
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Solution Overview
Problem
Current methods for installing coil groups in electrical machines, particularly in aerospace and aeronautical contexts, result in uncontrollable insulation displacement and compaction issues, compromising the reliability and repeatability of coil insulation, especially in pulse-width modulation electric motors.
Innovation Solution
A method involving sequential insertion and three-dimensional compaction of coil groups using preconfigured tooling to control insulation and compaction forces, followed by heating to fix the position of coils, ensuring precise shaping and reduced coil head size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If coil groups are installed in the conventional way by manually positioning and securing them in the stator slots, then installation flexibility is maintained, but the installation process is time-consuming and labor-intensive
Solution Approach 1:
The coil groups are pre-assembled with positioning elements and connection elements before installation. The positioning elements are attached to the coil groups in advance, and the connection elements are pre-positioned on the stator, enabling rapid assembly during installation without manual positioning adjustments
Solution Approach 2:
Positioning elements act as intermediaries between the coil groups and the stator slots, providing automatic alignment and positioning. Connection elements serve as intermediaries to securely attach the coil groups to the stator, eliminating the need for complex manual securing processes
2Manufacturing precision
If precise manual positioning is performed to ensure correct alignment of coil groups with stator slots, then positioning accuracy is achieved, but the installation process becomes time-consuming
Solution Approach 1:
Positioning elements are pre-attached to coil groups with precise dimensions and geometries that ensure correct alignment. The connection elements are pre-positioned on the stator with accurate spacing, eliminating the need for time-consuming manual measurement and adjustment during installation
Solution Approach 2:
The positioning elements serve as precision intermediaries that automatically ensure correct alignment between coil groups and stator slots through their pre-configured geometries, eliminating the need for manual positioning while maintaining high precision
3Ease of operation
If multiple separate operations are performed for positioning and securing coil groups, then installation flexibility is maintained, but the overall installation process becomes complex and time-consuming
Solution Approach 1:
The positioning and securing operations are merged into a single integrated action. The positioning elements and connection elements work together as a unified system, allowing the installer to position and secure coil groups in one operation rather than performing separate positioning and securing steps
Solution Approach 2:
Both positioning elements and connection elements are prepared in advance with all necessary positioning and securing features integrated. This preliminary preparation enables the installer to perform a single simplified operation during installation rather than multiple complex steps
Data Source
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AI summary
The invention relates to a method for installing coil groups in an electric machine (100), each coil group (104, 204) comprising at least one coil, each coil being composed of a plurality of turns of conductors, characterised in that it comprises, for each coil group (104, 204), the following installation steps applied to each coil group before being applied to the following coil group: a step of inserting a first coil group into at least two free or partially occupied slots (106) of the electric machine (100), the coil portions arranged outside the slots forming the coil heads, and a final shaping step in which the heads of the coils of said coil group are compacted into a predetermined shape, by a preconfigured tool.