Concentrated Winding Coil Bobbin Wire Alignment
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Solution Overview
Problem
Conventional concentrated winding coils face issues with low slot-fill rates due to wire alignment disturbances and high bobbin die manufacturing costs, which affect the efficiency and size of electric motors.
Innovation Solution
A concentrated winding coil design with a bobbin that has no guide grooves and uses a wire guiding/holding member to adjust wire alignment, ensuring accurate positioning and high slot-fill rates, while maintaining a shorter bobbin body length to reduce production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If guide grooves are provided on the bobbin body to guide wire alignment, then wire alignment precision is improved, but bobbin die manufacturing cost increases
Solution Approach 1:
The patent removes the guide grooves from the bobbin body, extracting the problematic feature that caused high manufacturing costs. Instead of relying on grooves molded into the bobbin, the invention uses a separate wire guiding/holding member that can be positioned and adjusted independently, thereby eliminating the need for complex bobbin die design while maintaining wire alignment precision.
Solution Approach 2:
The patent introduces a wire guiding/holding member as an intermediary component between the bobbin and the wire. This mediator element provides the necessary guidance and alignment functions without requiring modifications to the bobbin structure itself, thus avoiding the manufacturing cost penalty associated with grooved bobbins while still achieving precise wire positioning.
2Productivity
If wire is wound in regular helical form with constant wire traverse, then winding process simplicity is maintained, but slot-fill rate decreases due to useless space at start and end portions
Solution Approach 1:
The patent applies preliminary action by using the wire guiding/holding member to pre-position and align the wire before it is wound onto the bobbin. This preliminary alignment ensures that the wire is correctly positioned at the start of each turn, eliminating the useless space that normally occurs at the beginning and end of coil layers, thereby increasing the slot-fill rate without complicating the overall winding process.
Solution Approach 2:
The patent changes the parameter of wire positioning by introducing the wire guiding/holding member that can adjust wire traverse dynamically. This allows the wire to be positioned with precision during winding, transforming the regular helical winding into a more efficient pattern that minimizes gaps and maximizes slot-fill rate while maintaining process simplicity.
3Ease of manufacture
If bobbin body length is shortened to reduce production costs, then manufacturing cost decreases, but wire alignment control becomes more difficult
Solution Approach 1:
The wire guiding/holding member serves as a mediator that compensates for the reduced bobbin body length. By providing external guidance and holding functionality, this intermediary component ensures that wire alignment control is maintained even when the bobbin itself is shortened, thus achieving cost reduction without sacrificing manufacturing precision.
Solution Approach 2:
The patent moves the wire alignment control function from the radial dimension (grooves in the bobbin body) to an external dimension (wire guiding/holding member positioned around the bobbin). This dimensional shift allows the bobbin to be shortened while wire alignment is maintained through the external guiding mechanism, effectively decoupling bobbin length from alignment control capability.
Data Source
AI summary
A concentrated winding coil includes a plurality of coil layers each of which comprises a plurality of wire turns wound in alignment winding; and a bobbin including an inner flange, an outer flange and a bobbin body on which the wire is wound, wherein: each of the coil layers includes a turn shift portion where the wire is shifted from an n-th turn to an (n+1)-th turn; the turn shift portion is located only on a side of a coil end section of the coil; and the bobbin body has no guide grooves. A method of manufacturing the concentrated winding coil includes steps of: winding the wire on the bobbin; and pressing the wire by a wire guiding/holding member toward the inner flange or toward the outer flange.