Concentric Electrotechnical Coil Winding Geometry
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Solution Overview
Problem
Existing electrotechnical coils produced by casting have limitations in the number of turns due to minimum dimensions, restricting their application in electrical machines, especially at high speeds where current displacement issues arise, leading to inefficiencies and reduced fill factors.
Innovation Solution
The design involves arranging two or more windings in concentrically aligned planes perpendicular to a common coil axis, allowing for increased turns by optimizing winding geometry and production methods such as casting and metal forming, which enables a higher fill factor and reduced current displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional casting methods are used to produce electrotechnical coils, then the manufacturing process is simple and cost-effective, but the number of turns is limited due to minimum dimension constraints
Solution Approach 1:
The patent applies nesting by arranging multiple windings concentrically within the same winding plane, where inner windings are positioned inside outer windings. This allows multiple turns to be packed into the same spatial footprint, significantly increasing the number of turns without requiring additional radial or axial space, thereby resolving the contradiction between manufacturing simplicity and turn quantity.
Solution Approach 2:
The patent transitions from traditional planar winding arrangements to a three-dimensional concentric configuration within the winding plane. By utilizing the radial dimension for nested windings while maintaining the same winding plane orientation perpendicular to the coil axis, the design achieves higher turn density without complicating the casting process, thus maintaining ease of manufacture while increasing turn quantity.
2Loss of energy
If the number of turns is increased to improve machine efficiency, then current displacement is reduced, but the coil geometry becomes more complex and harder to manufacture
Solution Approach 1:
By nesting windings concentrically in the same winding plane, the patent achieves increased turn count without adding geometric complexity in terms of winding plane orientations or spatial arrangements. The nested configuration naturally reduces current displacement paths while maintaining a regular, manufacturable geometry that is compatible with conventional casting processes.
Solution Approach 2:
The patent applies local quality by varying the radial positions of different windings within the same winding plane, creating localized concentric zones. This allows each winding to be optimally positioned to minimize current displacement in its specific location, while the overall geometry remains simple and regular, avoiding global complexity.
3Quantity of substance
If windings are arranged in multiple winding planes to increase turns, then the fill factor improves, but the coil structure becomes more complex and occupies more space
Solution Approach 1:
The patent achieves high fill factor by nesting windings concentrically within the same winding plane, maximizing the utilization of the available winding space without requiring additional axial or radial dimensions. This approach increases the effective turn density and fill factor while keeping the coil volume compact, avoiding the space increase that would result from adding more winding planes.
Solution Approach 2:
The patent utilizes the radial dimension within the winding plane for nested concentric windings, achieving higher fill factor through optimized radial space utilization rather than extending the coil in axial or tangential directions. This maintains compact coil volume while improving the fill factor through efficient use of available space in the winding plane.
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 configuration allows for a significant increase in the number of turns, enhancing the efficiency of electrical machines by minimizing current displacement and maintaining cost-effectiveness, making them suitable for high-speed applications and compact designs.
Implementation Method 1
a coil material suitable for forming the winding(s), in particular an electrically conductive metal, is poured in liquid form into this negative mold, and wherein this coil material is solidified and/or allowed to solidify under controlled conditions
Data Source
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AI summary
In order to increase the number of turns that can be achieved for an electrotechnical coil and/or coil winding (100; 200; 300; 400) that is produced by means of casting and/or shaping and that comprises two or more turns (102-105; 202-205; 217-222; 302-305; 332-335), it is proposed that, at least to a large extent, each of the turns (102-105; 202-205; 217-222; 302-305; 332-335) are arranged at least essentially in a turn plane (101; 201; 208-211; 301, 331; 401, 431, 461) that is associated with this turn, wherein the turn plane (101; 201; 208-211; 301, 331; 401, 431, 461) is, at least to a large extent, at right angles to a coil axis (107; 207; 307) that is at least essentially common to all turns (102-105; 202-205; 217-222; 302-305; 332-335), at least two turns (102-105; 202-205; 217-222; 302-305; 332-335) in one or more of the turn planes (101; 201; 208-211; 301, 331; 401, 431, 461) being arranged at least essentially concentrically in one another at least in a fitted state. In addition, a method for producing an electrotechnical coil and/or coil winding (100; 200; 300; 400) of this kind with an increased number of turns and an electrical appliance having an electrotechnical coil and/or coil winding (100; 200; 300; 400) having an increased number of turns are proposed.