DC Motor Multilayer Wave Winding Coil End Optimization
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Solution Overview
Problem
Conventional direct-current motor wire winding methods result in increased coil end portion size and complexity due to overlapping coils, leading to challenges in applying forming loads without disconnection or insulation failure, and poor motor reliability due to exposed coil connecting wires.
Innovation Solution
The direct-current motor employs a multilayer-wave-winding structure where armature coils are wound to stride over two slots, with specific patterns to avoid overlaps at coil end portions, reducing the number of coil connecting wires on the outer surface and optimizing the winding process to minimize size and enhance reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wave winding method is used to wind armature coils, then the winding process can be simplified and coils can be sequentially wound, but the number of coil overlaps increases and coil end portions become large
Solution Approach 1:
The patent applies dimensional change by transitioning from a single-layer wave winding to a multilayer winding structure. Specifically, it divides the winding into a first layer with coils wound in a first direction and a second layer with coils wound in a second direction opposite to the first direction. This layered approach with opposite winding directions reduces the number of overlaps at coil end portions while maintaining the simplicity of the wave winding process.
2Volume of moving object
If forming load is applied to reduce coil end portion dimension, then compactness is improved, but coil connecting wires may experience disconnection or insulation failure
Solution Approach 1:
The patent extracts or removes the harmful element (coil connecting wires going across the outer surface of coil end portions) by changing the winding structure. The multilayer winding with opposite directions in different layers eliminates the need for coil connecting wires to traverse the outer surface of overlapping coil ends, thereby preventing disconnection and insulation failure while still allowing effective forming to reduce coil end portion dimensions.
3Ease of operation
If multiple coil connecting wires go across outer surfaces of overlapping coil end portions, then electrical connections are established, but the risk of disconnection and insulation failure increases
Solution Approach 1:
The patent converts the potential harm of having multiple coil connecting wires across overlapping surfaces into a benefit by using the multilayer structure with opposite winding directions. This structure naturally reduces the number of such wires needed, and the remaining connections are made in a more stable configuration where wires do not need to traverse the outer surface of overlapping coil ends, thereby improving connection stability while maintaining electrical connectivity.
Data Source
AI summary
The purpose of the present invention is to provide a direct current motor wherein the number of coil-connecting wires that cross the outer surface of a coil end part is reduced. In a direct current motor that is provided with an armature that has a plurality of armature slots and has an armature coil that is wound so as to span two armature slots that are separated by a fixed number of armature slots, a lowermost layer of a coil end part is provided with at least four armature coils that are wound through other armature slots so as not to coincide with the wound armature coil, and a layer above the four armature coils that are wound on the bottommost layer is provided with at least four armature coils that are wound in the same manner as the four armature coils.