Compressed Compressor Coil for Higher Power Density
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional coil stacks for electrically driven compressors have limited power density and efficiency due to suboptimal configuration and compaction of conductors, which restricts further enhancement of electrical machine performance.
Innovation Solution
A method involving the production of coils with deformed cross-sectional areas through compaction of windings using external force, reducing the coil's volume by 5-30% and optimizing its shape to fit snugly within the air gap of an electrical machine, allowing for increased power density and efficiency without additional geometric adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the current-carrying conductors of the coil are wound as closely as possible to one another, then the power density is increased, but the potential for further increasing the power density and degree of efficiency is not utilized
Solution Approach 1:
The patent applies parameter changes by deforming the cross-sectional shape of conductors from circular to rectangular or oval shapes, and by compacting the windings to reduce void spaces. This changes the physical parameters of the coil structure, allowing conductors to be packed more densely and efficiently, thereby increasing both power density and degree of efficiency simultaneously rather than trading one for the other
2Power
If the cross-sectional area of wires is deformed from circular to multi-sided shape through compaction, then the power density is increased, but the manufacturing process becomes more complex
Solution Approach 1:
The patent employs preliminary action by pre-forming the conductor cross-sections into rectangular or oval shapes before winding, and by using pre-designed molds with corresponding geometries. This preliminary preparation simplifies the subsequent compaction process during manufacturing, as the conductors are already optimized for dense packing, reducing the overall manufacturing complexity while achieving high power density
3Volume of moving object
If the outer dimensions of the coil are reduced through compaction, then the coil becomes more space-saving, but the manufacturing process requires additional external force application
Solution Approach 1:
The patent uses an intermediary mold as a mediating tool between the conductor windings and the compaction force. The mold with its precisely engineered cavity receives the wound conductors and applies distributed external force through its walls during compaction. This intermediary structure simplifies the manufacturing equipment requirements compared to direct force application, while achieving the desired volume reduction and dense packing
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
The method significantly increases power density and efficiency of the compressor coils, enabling a more compact and efficient design that maintains performance without power losses, suitable for use in internal combustion engine-driven compressors.
Implementation Method 1
a cross-sectional area of a wire of the first winding and of the second winding is deformed
Implementation Method 2
The first winding and the second winding are then compacted by virtue of an external action of force, wherein pressure is applied to the first winding and to the second winding, with the result that the outer dimensions of the coil (element) are reduced
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention proposes a method for producing a coil of a compressor (1) which can be electrically driven, and also a coil which is produced in accordance with this method, a stator and a compressor which can be electrically driven. The production process for the coil comprises the steps of: producing (100) a first winding (101) of the coil (12), producing (200) a second winding (102) of the coil (12), compacting (300) the first winding (101) and the second winding (102) by virtue of an external action of force, wherein a cross-sectional area (111, 112, 111', 112') of a wire of the first winding (101) and of the second winding (102) is deformed.