DC Motor Rotor Winding Segmentation for Reliability
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Solution Overview
Problem
Traditional DC motor manufacturing is time-consuming and costly due to the complex winding process of coils with many turns, which are prone to breakage, requiring thin and weak wires.
Innovation Solution
A DC motor design with a stator and rotor featuring a rotor winding composed of multiple layers of windings, where each layer consists of directly connected coils, allowing for a single continuous wire winding without cuts, reducing the number of turns and using thicker wires for increased reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional coil winding with many turns is used, then motor performance is maintained, but winding process time increases and manufacturing cost increases
Solution Approach 1:
The rotor winding is divided into multiple independent coil groups, each group consisting of multiple coils connected in series. This segmentation allows parallel winding of multiple coils simultaneously, reducing total winding time while maintaining the required total turns for motor performance.
Solution Approach 2:
The patent transitions from traditional single-layer winding to multi-layer winding structure, where coils are arranged in multiple layers around rotor teeth. This dimensional change enables more efficient space utilization and reduces the number of winding operations required.
2Reliability
If thin wires with small diameters are used for coils with many turns, then motor performance is maintained, but wire strength decreases and breakage risk increases
Solution Approach 1:
By dividing the total required turns into multiple coils connected in series, each individual coil can use fewer turns and thicker wire, improving wire strength and reducing breakage risk while maintaining the total effective turns needed for motor performance.
Solution Approach 2:
The patent changes the wire diameter parameter from thin (0.6mm or less) to thicker dimensions, which improves wire strength and durability. This parameter change is compensated by the segmented coil structure that maintains the required total turns through multiple parallel coil groups.
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
Significantly reduces winding time and improves motor reliability by using fewer turns per coil and thicker wires, maintaining performance comparable to traditional motors while enhancing durability.
Implementation Method 1
A rotor winding is received in the slots of the rotor core and connected to the segments of the commutator. The rotor winding comprises n layers of windings, wherein n is an integer smaller than P.
Data Source
AI summary
A commutated DC motor (10) includes a stator (12) and a rotor (14) mounted in the stator (12). The stator (12) has 2P magnetic poles, wherein P is an integer greater than 1. The rotor (14) includes a rotor shaft (81) with a rotor core (85), and a commutator (83) fixed thereto. The rotor core (85) has multiple teeth defining m×P slots therebetween, wherein m is an odd integer greater than 1. The commutator (83) has k×m×P segments, wherein k is 1 or 2. A rotor winding (87) formed by winding a single continuous wire is received in the slots of the rotor core (85) and connected to the segments of the commutator (83), and has k×m winding units. Each winding unit includes P coils in series connection and is directly connected to only two segments.