Continuous Stator Coil Winding for Rotating Machinery
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Solution Overview
Problem
Existing rotating machinery with distributed winding in slots faces productivity issues due to the need for numerous coil connections, particularly when using square wires, which increases complexity and reduces efficiency.
Innovation Solution
The use of continuous coils that straddle both inside and outside of slots, with extending portions winding continuously from the inside of the stator core to both axial ends, reducing the number of connections and improving productivity by allowing more efficient coil placement and winding configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If U-shaped segment coils are inserted into each slot, then the rotating machinery can be reduced in size and weight, but the number of coil connections increases and productivity deteriorates
Solution Approach 1:
Multiple U-shaped segment coils are merged into a single continuous coil that spans across multiple slots. Instead of inserting separate coils into each slot and connecting them, the invention uses one continuous coil that is inserted as a single piece, eliminating the need for multiple connections and improving productivity while maintaining the compact structure
2Weight of stationary object
If U-shaped segment coils are inserted into each slot, then the rotating machinery can be reduced in size and weight, but the number of connections increases and manufacturing complexity increases
Solution Approach 1:
Multiple separate coil connections are merged into a single continuous coil structure. The coil extends continuously from one slot through multiple slots without requiring intermediate connections, thereby reducing manufacturing complexity while achieving the same electromagnetic function with reduced weight
3Productivity
If continuous coils are used that straddle inside and outside of slots, then productivity is improved by reducing connections, but the coil configuration becomes more complex
Solution Approach 1:
The coil configuration transitions from a two-dimensional planar arrangement to a three-dimensional spatial structure that straddles inside and outside of slots. By utilizing the third dimension (radial direction), the coil can extend continuously across slot boundaries without requiring complex connections, thereby improving productivity while managing configuration complexity through spatial optimization
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 approach minimizes the number of connections, enhances coil occupancy within slots, and improves the efficiency and reliability of rotating machinery, while also reducing the size and weight of the machinery.
Implementation Method 1
an alternating current is supplied to the stator coils to generate a rotating magnetic field in the stator, and rotating torque is generated in a rotor by the rotating magnetic field
Data Source
AI summary
A rotating machinery is to be provided wherein coils can be wound round a stator core in a minimized state of connected parts. In a rotating machinery comprising a stator formed annularly and a rotor disposed rotatably on the inner periphery side of the stator, the stator comprises a stator core, the stator core having in the circumferential direction a plurality of slots each having a coil inserting portion on the inner periphery side, and coils wound by lap winding within the slots, at least the lap-wound winding portion of the coils in each slot being constituted by a continuous line and wound at a coil end so as to straddle the inner periphery side and the outer periphery side of the slot. According to this construction there is no increase in the number of connected parts even if the number of turns in the winding portion is increased.