Multi-Layer Edgewise Coil Winding for High Fill Factor
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Solution Overview
Problem
Existing edgewise coils face challenges in achieving higher copper fill factors and thermal conductivity while preventing wire deformation during winding, especially with thicker wires, which limits their force or torque generation and thermal performance.
Innovation Solution
A winding assembly and method that uses a wire guiding unit and pressing units to guide and deform thin wires with a rectangular cross-section, ensuring they follow a sufficient circumference angle and curvature, allowing for controlled deformation and stacking, thereby enhancing copper fill factor and thermal contact conductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If thicker wires are used in edgewise coils, then the copper fill factor and force generation improve, but wire deformation during winding occurs
Solution Approach 1:
The wire is pre-formed with a curved shape matching the winding core circumference before the winding process begins. This preliminary shaping ensures that when the wire is wound onto the core, it naturally conforms to the curvature without deforming, enabling the use of thicker wires for higher copper fill factors while maintaining manufacturing precision
Solution Approach 2:
The invention changes the physical state and shape parameters of the wire by pre-curving it to match the winding core's geometry. This parameter adjustment allows the wire to be wound without deformation, resolving the contradiction between using thicker wires for better performance and preventing wire deformation during the winding process
2Temperature
If wire curvature is increased to follow winding core, then thermal contact conductance improves, but wire deformation occurs
Solution Approach 1:
The wire is pre-curved to match the winding core's circumference before winding. This preliminary action ensures the wire already has the necessary curvature for good thermal contact with the core, eliminating the need to increase curvature during winding and thus preventing wire deformation while maintaining high thermal contact conductance
3Temperature
If wire thickness is increased for better thermal conductivity, then thermal performance improves, but wire handling and winding difficulty increase
Solution Approach 1:
Thicker wires are pre-formed with the appropriate curvature before the winding process. This preliminary shaping makes them easier to handle during winding since they naturally conform to the core geometry, reducing winding difficulty while maintaining the thermal conductivity benefits of thicker wires
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 assembly enables the production of edgewise coils with improved copper fill factors and thermal contact conductance, enabling higher force or torque generation and better thermal conductivity per unit volume.
Implementation Method 1
The at least one wire guiding unit is configured for arranging the wire with one of its first side surfaces on the winding core... enabling the production of edgewise coils with improved copper fill factors and thermal contact conductance
Implementation Method 2
The assembly further comprises a first pressing unit... presses, in a direction from the first end surface to the second end surface, onto a second side surface of the wire arranged on the winding core
Implementation Method 3
After having wound wire 2, the combination of winding core 10 and wire 2 is subjected to a heating step. During this step, surrounding layer 5 will melt thereby forming a body of surrounding layer 5 in which conductive inner cores 3 and insulating layers 4 are fixated
Data Source
AI summary
The present invention relates to an assembly for winding an edgewise coil. The present invention further relates to a multi-layer edgewise coil. The assembly comprising a winding core. at least one wire guiding unit for receiving a wire. a first pressing unit, and a drive shaft for rotating the winding core relative to the at least one wire guiding unit. The at least one wire guiding unit comprises a channel for guiding the wire that follows at least a part of a circumference of the winding core. preferably over an angle exceeding 30 degrees. The assembly is configured for operating in a first mode in which mode the first pressing unit presses. in a direction from the first end surface to the second end surface. onto a second side surface of the wire arranged on the winding core at least during winding of a first layer of the wire on the winding core by means of rotating the winding core relative to the at least one wire guiding unit.