DC Motor Inter-Core Conductors for High Space Factor
Solution Overview
Problem
Existing field winding type motors face a challenge in achieving a high space factor due to the need for spacing between adjacent field coils to prevent interference, which reduces their compactness and output.
Innovation Solution
The design incorporates inter-core conductors that extend axially between circumferentially adjacent pole cores, formed by integrating conductor parts to generate magnetic fields for both poles, allowing for closer placement without interference and increasing the space factor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If regular wound coils are used to increase space factor, then motor output is improved, but adjacent field coils interfere with each other
Solution Approach 1:
The field conductor is segmented into multiple independent conductors (first field conductor, second field conductor, third field conductor) positioned at different radial locations. Each conductor is independently wound and positioned, allowing them to generate magnetic fields for different pole cores without interfering with each other. This segmentation enables closer spacing while maintaining reliability.
Solution Approach 2:
The invention transitions from a single-layer coil arrangement to a multi-layer radial arrangement. Field conductors are positioned at different radial distances from the rotation axis, creating a three-dimensional spatial distribution. This dimensional change allows conductors to be closer in the radial direction without causing interference, thereby increasing the space factor while maintaining reliability.
2Reliability
If space is left between adjacent field coils to avoid interference, then reliability is improved, but space factor is reduced
Solution Approach 1:
By dividing the field winding into multiple independent conductors positioned at different radial locations, the invention eliminates the need for large spacing between adjacent coils. Each segmented conductor can be tightly positioned without interfering with others, maximizing the utilization of available space while maintaining reliability.
Solution Approach 2:
The multi-layer radial arrangement creates a nested structure where field conductors are positioned at different radial levels, similar to nested dolls. This nesting allows conductors to occupy different spatial zones without requiring additional clearance between them, thereby increasing the space factor while preventing interference.
3Ease of manufacture
If edgewise-wound field coils are used, then winding is simplified, but space between coils must be maintained reducing space factor
Solution Approach 1:
The field conductor is segmented into multiple independent conductors that can be wound and positioned separately. Each conductor follows a simplified edgewise-winding pattern, but the segmentation allows them to be arranged in multiple radial layers, eliminating the need for large spacing while maintaining manufacturing simplicity.
Solution Approach 2:
The invention maintains the simple edgewise-winding technique but applies it across multiple radial dimensions. By positioning conductors at different radial distances, the simple winding process is preserved while the multi-dimensional arrangement eliminates the need for large spacing, thereby increasing the space factor.
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 configuration enables a compact and high-output DC motor with improved space factor utilization, preventing interference and allowing for efficient magnetic flux distribution, leading to enhanced power output and reduced size.
Implementation Method 1
a field conductor that generates a magnetic field to magnetize the pole cores when supplied with a current
Implementation Method 2
each of the inter-core conductors being formed by integrating a first conductor part that generates a magnetic field to be applied to one of the circumferentially adjacent pole cores and a second conductor part that generates a magnetic field to be applied to the other of the circumferentially adjacent pole cores
Data Source
AI summary
A DC motor includes a cylindrical yoke constituting a magnetic path, pole cores fixed to an inner periphery of the yoke so as to be arranged at even intervals along a circumferential direction of the yoke, and a field conductor that generates a magnetic field to magnetize the pole cores when supplied with a current. The field conductor includes inter-core conductors each of which extends in an axial direction of the yoke so as to be disposed between circumferentially adjacent pole cores. Each of the inter-core conductors is formed by integrating a first conductor part that generates a magnetic field to be applied to one of the circumferentially adjacent pole cores and a second conductor part that generates a magnetic field to be applied to the other of the circumferentially adjacent pole cores.