Conductor Array for Electrical Machine Windings
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Solution Overview
Problem
Existing windings for electrical machines lack flexibility in combining conductors to achieve desired voltage/current combinations and are inefficient in manufacturing complex connections without the issues associated with compacted conductive wires.
Innovation Solution
An array of conductors with specific geometric arrangements and interconnection zones allows for flexible formation of coils, enabling various combinations of series and parallel connections, and includes a flexible insulating layer for efficient manufacturing and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional compacted conductive wires are used for winding, then the winding structure is compact, but the manufacturing of complex connections becomes difficult and problematic
Solution Approach 1:
The winding structure is segmented into modular units (U-shaped conductors, individual coils) that can be independently manufactured and then assembled. This segmentation allows complex connections to be made through simple modular assembly rather than complex wire manipulation, resolving the contradiction between ease of manufacture and device complexity.
Solution Approach 2:
A flexible circuit board is introduced as an intermediary substrate that carries the conductive traces and provides the connection structure. This intermediary element handles the complexity of connections on the board level, allowing the overall winding assembly to be manufactured easily through standard PCB techniques rather than complex wire winding processes.
2Adaptability or versatility
If conductors are combined in fixed configurations, then the winding structure is simple, but the flexibility in achieving desired voltage/current combinations is limited
Solution Approach 1:
The winding structure incorporates switchable and reconfigurable connection elements that allow the electrical configuration to be dynamically changed. Coils can be connected in series or parallel through switchable contacts, enabling the same physical structure to adapt to different voltage and current requirements without requiring multiple fixed configurations.
Solution Approach 2:
The modular coil design with standardized terminals and switchable connections creates a universal structure that can serve multiple functions. The same basic coil unit can be configured for different voltage levels, current ratings, and connection topologies, providing versatility without increasing the fundamental structural complexity.
3Adaptability or versatility
If a large number of coils are arranged in parallel to reduce terminal voltage amplitude, then the line current amplitude increases, but the control over voltage/current combination becomes more complex
Solution Approach 1:
The control system monitors the actual voltage and current at the terminals and provides feedback to adjust the switching configuration of the coils. This feedback mechanism allows the system to automatically maintain desired operating characteristics regardless of whether coils are connected in series or parallel, simplifying the ease of operation while preserving adaptability.
Solution Approach 2:
The winding structure incorporates automatic balancing mechanisms where the modular design and switching system automatically equalize the current distribution among parallel coils or voltage distribution among series coils. This self-service feature reduces the complexity of external control systems while maintaining ease of operation.
Data Source
AI summary
The disclosure relates to array of conductors for a winding for an electrical machine wherein a first group of conductors extend on a first surface parallel to a reference surface, comprising N_s subgroups each having N_c first conductors, and a second group of second conductors extend on a second surface parallel to said reference surface, comprising also N_s subgroups each having N_c second conductors. First conductors of the first group overlap second conductors of the second group at interconnection zones, comprising upper interconnection zones and lower interconnection zones opposite to the upper interconnection zones with respect to the curve, where first conductors may be connected to second conductors for forming coils. The disclosure also relates to a winding comprising such an array and to an electrical machine comprising such a winding.