Electromagnetic Mat for Electric Machine Stator Winding
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Solution Overview
Problem
Current methods for producing electric machine components, such as stator or rotor components, are costly and inflexible, lacking a scalable and customizable approach for creating high-performance electric motors and generators.
Innovation Solution
The development of an electromagnetic mat comprising structural and winding fibre lengths, which are woven into a support structure to form a customizable and efficient stator or rotor component, allowing for various winding patterns and designs through a method that includes weaving, twining, or braiding, enabling the production of electric machines with tailored properties and geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automatic winding equipment is used to form windings of an electric machine, then the windings can be produced with consistent quality, but the production cost increases and design flexibility is reduced
Solution Approach 1:
The invention segments the winding structure into discrete fibre lengths that can be independently positioned and arranged in the electromagnetic mat, allowing flexible configuration without complex winding equipment while maintaining consistent quality through precise fiber placement
Solution Approach 2:
Instead of forming windings through traditional winding processes using expensive automatic equipment, the invention inverts the approach by pre-arranging conductive fibres in a mat structure before assembly, achieving the same functional result with simpler, more cost-effective manufacturing
2Productivity
If automatic winding equipment is used to form windings of an electric machine, then standardized production can be achieved, but design customization and flexibility are limited
Solution Approach 1:
The electromagnetic mat structure allows dynamic reconfiguration of fibre arrangements to create different winding patterns and machine designs, enabling both standardized production and custom designs using the same basic manufacturing platform
Solution Approach 2:
The invention enables design customization by changing parameters such as fibre arrangement patterns, fibre lengths, and mat dimensions without requiring different manufacturing equipment, allowing flexible adaptation to various machine designs while maintaining standardized production processes
3Ease of manufacture
If traditional winding methods are used, then production steps are numerous and costs are high, but a flexible and customizable method is needed
Solution Approach 1:
The invention merges the winding structure with the electromagnetic mat into a single integrated component, eliminating separate winding steps and reducing manufacturing complexity while maintaining the ability to create various winding patterns through fibre arrangement
Solution Approach 2:
The conductive fibres are pre-arranged in the electromagnetic mat before assembly, performing the winding configuration action in advance during mat fabrication, which simplifies the overall production process while enabling design flexibility through custom fibre patterns
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 reduces production costs and enhances the customizability of electric machine components, enabling the creation of high-performance electric machines with improved electromagnetic, mechanical, and thermal properties, while simplifying the production process and allowing for a wide range of applications.
Implementation Method 1
the conductive fibres are connectable to a source of electricity to generate a magnetic field for operating the composite drive unit
Data Source
AI summary
A method of producing an electromagnetic mat for forming a stator or rotor component of an electric machine. The electromagnetic mat has structural fibre lengths and a plurality of winding fibre lengths for forming a winding fibre that is in a winding pattern for forming one or more windings of the electric machine. The electromagnetic mat is formed by forming a support structure with the structural fibre lengths and inserting the winding fibre lengths into the support structure so that the winding fibre lengths extend across the structural fibre lengths and the structural fibre lengths lock the winding fibre lengths in position.