Electric Machine Coil Head Shaping for Insulation Control
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Solution Overview
Problem
Current methods for installing coil groups in electric machines, particularly in the aeronautical and space industries, face challenges in ensuring reliable insulation and controlled compacting, leading to unpredictable conductor movements and compromised insulation quality, especially in electric motors with pulse width modulation power supply.
Innovation Solution
A method involving definitive shaping of coil heads using a preconfigured apparatus before subsequent coil group installation, allowing controlled compacting and insulation placement, with optional temperature treatment to secure coil positions, and using specialized tools for three-dimensional compacting to minimize conductor movement and ensure reproducibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If final compacting is performed after all coils are inserted, then coil head size is reduced, but insulation control between coils deteriorates due to uncontrolled conductor movement
Solution Approach 1:
The patent divides the coil installation process into sequential steps where coil groups are installed and compacted individually rather than installing all coils first and then compacting. This segmentation allows each coil group to be compacted to a predetermined shape before the next group is installed, preventing uncontrolled conductor movement and maintaining insulation reliability while still achieving reduced coil head size.
Solution Approach 2:
The patent applies preliminary compacting to each coil group immediately after insertion, shaping the coil heads to a predetermined form before subsequent coils are installed. This preliminary action prevents the need for final compacting that would cause uncontrolled movement, thereby maintaining both reduced coil head size and insulation reliability.
2Ease of operation
If manual shaping of coil heads is performed during coil installation, then flexibility in installation is maintained, but manufacturing precision and reproducibility deteriorate
Solution Approach 1:
The patent introduces a predetermined-shaped mold or form as an intermediary tool during the coil installation process. This mold guides the compacting operation to achieve the desired predetermined shape consistently, combining the flexibility of manual installation with the precision of controlled shaping, thereby improving manufacturing precision without sacrificing installation flexibility.
3Ease of manufacture
If loose flexible wire conductors are used, then ease of insertion is improved, but conductor position control deteriorates during compacting operations
Solution Approach 1:
The patent applies preliminary compacting to each coil group immediately after insertion to secure the loose flexible wire conductors in their proper positions before subsequent operations. This preliminary action maintains the insertion ease of loose conductors while preventing position control deterioration during later compacting operations by establishing stable positions early in the process.
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
This method guarantees reliable insulation and reduced coil head size, enhancing reproducibility and insulation reliability by controlling conductor movements and compacting forces, facilitating easier insulation placement and reducing the risk of insulation displacement during installation.
Implementation Method 1
a definitive shaping step by compacting the heads of the coils of said coil group into a predetermined shape, by a preconfigured apparatus
Data Source
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, characterized 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, a definitive shaping step by compacting the heads of the coils of said coil group into a predetermined shape, by a preconfigured apparatus.