Coupled Coil Unit Forming for Simpler Motor Coil Connections
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Solution Overview
Problem
Conventional methods for connecting coils in motors are limited by complex configurations, leading to larger apparatus sizes and complicated connection processes, hindering miniaturization and productivity in high-output motors, particularly those used in electric vehicles.
Innovation Solution
A manufacturing method involving winding a conductor to form a coil coupled body with a coupling portion and deforming at least one coil relative to others, followed by annealing and coating with insulating resin, allowing for simplified and efficient production of coil units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connecting methods (welding, screwing) are used to connect coils to an annular bus bar, then the coils can be connected, but the configuration becomes complicated and apparatus size increases
Solution Approach 1:
The invention divides the coil structure into multiple independent coils that can be connected through a coupling portion. Each coil can be manufactured separately and then assembled, simplifying the overall configuration and reducing apparatus size while maintaining connection reliability through the standardized coupling interface
Solution Approach 2:
The invention merges multiple coils into a single integrated coil unit through a coupling portion, allowing them to function as one unit while maintaining individual coil characteristics. This reduces the number of separate connection operations needed and simplifies the overall system configuration
2Reliability
If conventional connecting methods are used, then coils can be connected, but the connecting process becomes complicated and productivity decreases
Solution Approach 1:
The invention performs preliminary actions by pre-assembling multiple coils into a coupled body before final installation. The coupling portion is designed to allow rapid assembly of pre-formed coils, reducing the complexity and time of the connecting process during mass production while ensuring reliable connections
Solution Approach 2:
The invention changes the connection method from traditional welding or screwing to a deformation-based coupling method. By deforming the coupling portion to mechanically interlock coils, the process becomes faster and more suitable for mass production while maintaining connection reliability
3Reliability
If coils are arranged side by side in annular pattern and connected to annular bus bar, then connection is achieved, but miniaturization is limited
Solution Approach 1:
The invention applies nesting by placing multiple coils in a compact coupled body configuration where they share common structural elements and coupling portions. This nested arrangement reduces the overall volume required for the same number of coils compared to traditional annular arrangements with separate bus bar connections
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 method enhances productivity and reduces manufacturing complexity, enabling cost-effective mass production of coil units suitable for high-performance motors.
Implementation Method 1
a deforming step of deforming so that at least one coil, out of the plurality of coils, moves relative to the other coils
Implementation Method 2
followed by annealing and coating with insulating resin
Data Source
AI summary
A manufacturing method of a coil unit includes a step of winding a conductor to form a coil coupled body constituted of a coupling portion and a plurality of coils that have been coupled through the coupling portion, and a deforming step of deforming so that at least one coil, out of the plurality of coils, moves relative to the other coils.