Coreless Electric Machine Magnet Coil Segmentation
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Solution Overview
Problem
Existing coreless electric machines face challenges in forming coil assemblies due to interference between magnet coils and issues with localized excessive expansion or breakage of coil conductive wires, particularly when multiple magnet coils are combined.
Innovation Solution
A coreless electric machine design featuring a rotor with a permanent magnet and a stator comprising a combination of 2N magnet coils, where each coil is configured as a concentrated winding coil with specific bent ends and an air core region, arranged alternately to prevent interference, and made from a conductive wire bundle with an insulating coating to reduce expansion and breakage risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If magnet coils are arranged at positions in intimate contact with each other to increase coil wire density and reduce gap, then efficiency is improved, but interference between magnet coils occurs causing difficulty in forming coil assembly
Solution Approach 1:
The magnet coils are segmented into two distinct shape types (first shape coils with inwardly bent first coil end parts, and second shape coils with outwardly bent second coil end parts). This segmentation allows alternating arrangement that prevents interference while maintaining high density
Solution Approach 2:
The magnet coils employ asymmetric bending directions for their end parts (inward for first shape, outward for second shape), creating complementary geometries that fit together without interference when arranged alternately
2Productivity
If magnet coils are arranged at positions in intimate contact with each other, then efficiency is improved, but localized excessive expansion or break of coil conductive wire occurs
Solution Approach 1:
The coil conductive wire is segmented into multiple non-insulated conductive wires bundled together, which distributes stress and prevents localized excessive expansion or break of individual wires
Solution Approach 2:
The coil conductive wire uses a composite structure combining multiple non-insulated conductive wires with an insulating coating layer, providing both electrical conductivity and mechanical flexibility to prevent wire breakage
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 design facilitates the assembly of multiple magnet coils by preventing interference and reducing the occurrence of coil breakage, enabling higher coil wire density and minimizing torque ripple and vibration due to equal electrical resistance in all coils.
Implementation Method 1
each of the magnet coils is made of a coil conductive wire including a conductive wire bundle as a bundle of multiple non-insulated conductive wires each being a non-insulated wire, and an insulating coating layer covering periphery of the conductive wire bundle
Data Source
AI summary
A coil assembly of a stator is configured in such a manner that an air core region of each magnet coil houses effective coil parts of different magnet coils. The outer shape of each magnet coil in a section perpendicular to a center axis of a rotor is a divided ring-like shape defined by dividing a circular ring into equal N parts. Two sides of the divided ring-like shape form an angle set to be 360°/N or less. Each magnet coil is made of a coil conductive wire including a conductive wire bundle as a bundle of multiple non-insulated conductive wires each being a non-insulated wire, and an insulating coating layer covering the periphery of the conductive wire bundle.