Coil Winding Compression for Higher Space Factor Motors
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Solution Overview
Problem
The challenge of forming a coil with a conductor and insulation layer using three-dimensional additive manufacturing is the significant difference in physical properties between these materials, leading to instability and a decrease in space factor.
Innovation Solution
A method involving forming a winding portion with a deformation allowing portion of lower rigidity, applying an insulation film, and compressing the winding portion to create a coil with a higher space factor, including features like grooves or notches to facilitate deformation and ensure uniform insulation thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conductor and an insulation layer are simultaneously formed by three-dimensional additive manufacturing, then integral formation is achieved, but stable forming becomes difficult due to significantly different physical property values of the materials
Solution Approach 1:
The patent segments the formation process into two separate steps: first forming the conductor, then forming the insulation layer. This segmentation allows each material to be formed under optimized conditions for its specific physical properties, avoiding the instability that arises from attempting to form both materials simultaneously with vastly different characteristics.
Solution Approach 2:
The conductor is formed in advance as a preliminary step before forming the insulation layer. This preliminary action establishes a stable foundation that allows subsequent insulation layer formation to proceed reliably, as the conductor's physical properties no longer interfere with the insulation material deposition process.
2Reliability
If the thickness of the insulation layer is increased to achieve stable forming, then forming stability is improved, but the space factor of the coil is decreased
Solution Approach 1:
By forming the conductor first as a preliminary step, the patent enables precise control of the insulation layer thickness. The pre-formed conductor serves as a stable substrate that allows the insulation layer to be applied at optimized minimal thickness while maintaining forming stability, thereby preserving maximum space factor.
3Volume of moving object
If the winding portion is compressed in the direction of the axis, then the space factor is increased, but the uniformity of the insulation film may be compromised
Solution Approach 1:
The insulation film is formed in advance on the conductor before the compression step. This preliminary action ensures that the film is applied uniformly to the conductor's surface in its uncompressed state. Subsequent compression then uniformly reduces the overall coil volume while maintaining the film's uniformity, as the film was already established in its optimal state before deformation occurred.
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 approach allows for a stable and efficient manufacturing process that increases the space factor of the coil, enhances electrical conductivity, and improves the performance of the electric motor by maintaining a determinate shape and reducing manufacturing costs.
Implementation Method 1
a deformation allowing portion formed at a portion of the winding portion in an extending direction of the winding portion and having a lower rigidity than the other portion
Data Source
AI summary
A method of manufacturing a coil includes: a step of forming a winding portion extending twisting around an axis along a direction of the axis, the winding portion including a portion in an extending direction of the winding portion, the portion being a deformation allowing portion having a lower rigidity than the other portion; a step of forming an insulation film on the winding portion in the extending direction of the winding portion; and a step of compressing the winding portion on which the insulation film is formed, in the direction of the axis.