Coreless Stator Coil Winding Unit Hybrid Overlapping Non-Overlapping Design

Solution Overview

Problem

Coreless stator motors with non-overlapping coil winding assemblies have inferior performance in back electromotive force constant and torque constant compared to overlapping coil winding assemblies, necessitating an enhancement in torque output.

Innovation Solution

A coreless stator coil winding unit comprising an overlapping coil winding assembly with first and second coils arranged annularly with a phase difference and a non-overlapping coil winding assembly with third coils located between the first and second coils, utilizing a printed circuit board to separate coils and optimize coil pitch to ⅚π, thereby improving performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a non-overlapping coil winding assembly is used, then the manufacturing process is simpler, but the back electromotive force constant and torque constant are inferior

Engineering Contradiction:

Improvecoil winding processVSAvoidback electromotive force constant and torque constant

Core Design Contradiction:

Ease of manufactureVSPower

Solution Approach 1:

The patent combines both overlapping and non-overlapping coil winding assemblies into a single hybrid structure. The overlapping coils (first and second coils) provide high back electromotive force and torque constants, while the non-overlapping coils (third coils) fill the gaps between them to improve space utilization. This merging of two different winding approaches resolves the contradiction by achieving high performance without sacrificing manufacturing simplicity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The stator is divided into different coil winding regions: overlapping coil regions and non-overlapping coil regions. Each region serves a specific function - the overlapping regions optimize electromagnetic performance while the non-overlapping regions optimize space utilization. This segmentation allows each part to be optimized for its specific purpose while working together as a unified system.

Inventive Principle:

Principle #1Segmentation

2Power

If an overlapping coil winding assembly is used, then the back electromotive force constant and torque constant are improved, but the coil space factor is reduced

Engineering Contradiction:

Improveback electromotive force constant and torque constantVSAvoidcoil space factor

Core Design Contradiction:

PowerVSQuantity of substance

Solution Approach 1:

The stator is divided into different coil winding regions: overlapping coil regions and non-overlapping coil regions. Each region serves a specific function - the overlapping regions optimize electromagnetic performance while the non-overlapping regions optimize space utilization. This segmentation allows each part to be optimized for its specific purpose while working together as a unified system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines both overlapping and non-overlapping coil winding assemblies into a single hybrid structure. The overlapping coils (first and second coils) provide high back electromotive force and torque constants, while the non-overlapping coils (third coils) fill the gaps between them to improve space utilization. This merging of two different winding approaches resolves the contradiction by achieving high performance without sacrificing manufacturing simplicity.

Inventive Principle:

Principle #5Merging (Combining)

3Power

If coils are arranged with optimal pitch for performance, then the back electromotive force constant and torque constant are improved, but the risk of electrical breakdown between adjacent coils increases

Engineering Contradiction:

Improveback electromotive force constantVSAvoidelectrical breakdown risk

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

A printed circuit board is introduced as an intermediary component between adjacent coils (specifically between the first coils and third coils, and between second coils and third coils). This PCB acts as an insulating barrier that prevents electrical breakdown while allowing the coils to maintain their optimal pitch for high back electromotive force and torque constants. The intermediary structure resolves the contradiction by providing electrical isolation without compromising the electromagnetic performance.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

The proposed design enhances space utilization, back electromotive force constant, torque constant, and output power of the motor, while preventing electrical breakdown by strategically arranging coils on a printed circuit board.

Implementation Method 1

The stator is equipped with coils for introducing current, thereby generating an induced electromotive force to rotate the rotor.

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS11677303B2Motor and coreless stator coil winding unit thereof

Publication Date: 2023.06.13 NAT CHENG KUNG UNIV

AI summary

A motor and a coreless stator coil winding unit thereof are disclosed. The coreless stator coil winding unit includes an overlapping coil winding assembly and a non-overlapping coil winding assembly. The overlapping coil winding assembly includes a plurality of first coils arranged annularly and a plurality of second coils arranged annularly. The first coils and the second coils overlap with a phase difference. The non-overlapping coil winding assembly includes a plurality of third coils arranged annularly. The third coils are each located between an adjacent one of the first coils and an adjacent one of the second coils. Thus, the back electromotive force constant and torque constant of the motor have a better performance.