Electromagnetically Excitable Coil Wire Crossing Design
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Solution Overview
Problem
In large-format electrical machines, coils with an odd number of turns face challenges in guiding the wire from the last turn to the starting end without increasing the coil's width in the circumferential direction, which can lead to wire slippage and damage to the insulation.
Innovation Solution
The coil design features a wire crossing on the shorter side of the cross-section, with at least three winding layers, where the outermost layer is wound over only part of the coil, and the layer below it has winding gaps to securely guide the wire back to the starting end without widening the coil, and strategically placed gaps prevent wire slippage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the wire is guided from the radial inside back to the radial outside after the last turn, then the coil can be completed, but the coil width in the circumferential direction increases
Solution Approach 1:
The wire is guided through the axial dimension (from radial inside to radial outside via the axial end) rather than directly in the circumferential direction, thereby avoiding an increase in coil width while still completing the coil structure
Solution Approach 2:
The wire path is nested within the existing coil structure by guiding it through the axial end and back through the winding layers, utilizing the internal space of the coil rather than expanding outward
2Volume of moving object
If the wire is positioned steeply after the wire crossing in a long coil, then space is utilized, but the wire may slip out of position and damage insulation
Solution Approach 1:
The wire angle parameter is changed from a steep position to a flatter position (between 60° and 120° relative to the coil axis), which reduces the risk of slippage while still achieving adequate space utilization
Solution Approach 2:
The wire crossing is positioned and secured in advance to prevent future slippage, and the wire is guided through winding gaps to preemptively secure its position before operational stresses could cause displacement
3Area of stationary object
If the outermost winding layer is wound over the entire coil, then coverage is maximized, but wire guidance and positioning become difficult without widening the coil
Solution Approach 1:
The outermost winding layer is segmented to be wound over only part of the coil, with winding gaps provided to facilitate wire guidance and positioning without requiring the layer to cover the entire coil length
Solution Approach 2:
Winding gaps act as intermediaries that facilitate the wire's transition and positioning, allowing the wire to be guided through the coil structure without direct contact that would require full coverage
Data Source
Figure 1a~1c
Figure 2a~2b
Figure 3a~3b
AI summary
The invention relates to an electromagnetically excitable coil (10) comprising a wire (13) which is wound in a winding direction about a wire holder (16), the beginning (31) of a winding, arranged essentially on a first end (34) of the coil (10), and the end (49) of a winding arranged essentially on the same end (34) of the coil (10). Said coil also comprises an uneven number of winding layers (28) and has a long cross-section (40) having a longer side (43) and a shorter side (46). The wire (13) is guided from the second end (55) of the coil (10) to the first end (34) of the coil (10), forming at least one wire intersection (52) on the shorter side of the cross-section (40).