Coil Unit Arrangement Device for Compact Motor Winding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for manufacturing multiple-winding coils face challenges such as increased wire resistance, complex wire management, and interference between jumper wires as the number of coils increases, making it difficult to compact the forming space and efficiently arrange coil units in a motor.
Innovation Solution
A coil unit arrangement device that extracts and arranges coils based on stator arrangement orders, allowing jumper wires to be aligned on the same side, preventing crossings, and enabling compact workspace utilization without relative movement of central axes, simplifying the arrangement process and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple coils are formed from one coil raw wire to reduce wire connection resistance, then electrical resistance is reduced, but the forming space becomes larger and wire management becomes more complex
Solution Approach 1:
The coil raw wire is divided into multiple coil sections (first coil, second coil, third coil, etc.) along its length. Each coil section is independently formed and positioned, allowing compact arrangement while maintaining electrical continuity through jumper wires. This segmentation enables multiple coils to be created from one raw wire without requiring excessive forming space.
Solution Approach 2:
Coil units are arranged in multiple layers (first layer, second layer, etc.) with different height levels. The arrangement transitions from a single-plane configuration to a three-dimensional stacked configuration, reducing the horizontal forming space while accommodating multiple coils from one raw wire.
2Volume of moving object
If coils are arranged in multiple layers with decreasing height levels, then forming space is compacted, but jumper wire interference and crossing increase
Solution Approach 1:
Jumper wires are extracted and routed separately from the main coil windings. Each jumper wire is individually managed to connect corresponding coils across layers, preventing interference with the coil formation process and eliminating wire crossings by providing dedicated connection paths.
Solution Approach 2:
The positions of jumper wires are predetermined and pre-planned in the coil unit design. Jumper wires are positioned and secured before coil formation begins, ensuring they do not interfere with subsequent coil winding operations and preventing crossing issues in advance.
3Ease of manufacture
If conventional arrangement methods are used, then coil units can be arranged in stator positions, but the process becomes complex and efficiency decreases
Solution Approach 1:
Coil units are pre-assembled with all coils and jumper wires properly positioned and secured before being transported to the stator. This preliminary assembly eliminates complex on-site arrangement operations and enables efficient installation by simply placing pre-configured coil units into their designated stator positions.
Solution Approach 2:
The coil unit structure is designed to be self-aligning and self-securing. Features such as positioning protrusions, guiding grooves, and snap-fit connections enable the coil unit to automatically assume its correct position and orientation in the stator without requiring complex external arrangement equipment or procedures.
Data Source
Figure 1A~2
Figure 3A~4
Figure 5~6
AI summary
There is configured a coil unit arrangement device that forms an array coil group by arranging in a predetermined arrangement order each relevant coil of a coil unit in which a plurality of coils corresponding to a plurality of phases is connected by a jumper wire for each phase, the coil unit arrangement device including: a holding section provided with a rotatable coil unit support that supports the coil unit; and a receiving section provided with an array coil group support that supports the array coil group, the receiving section relatively turning with respect to the holding section.