Endless Wave Winding Segmented Blade for Magnetic Symmetry
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Solution Overview
Problem
In multi-layer wave windings of electrical machines, unintentional interchanging of electrical conductors at layer jumps leads to asymmetrical magnetic fields, reducing performance, and existing methods do not effectively address this issue to reduce manufacturing costs and enhance performance.
Innovation Solution
A method for producing an endless wave winding where electrical conductors are wound around a winding sword with alternating sequences, with sections pivoted 180° to maintain symmetry, and the conductors are heated to reduce stress during winding direction changes, ensuring consistent winding direction and sequence alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electrical conductors are wound around a winding blade in multi-layer wave windings, then the wave winding structure is formed, but unintentional exchange of partial windings occurs at layer transitions leading to asymmetrical magnetic fields
Solution Approach 1:
The winding blade is divided into multiple sections (first section, second section, third section) that can be independently pivoted. This segmentation allows each section to control the winding direction of specific sequences, enabling precise control over conductor arrangement at layer transitions to prevent unintended exchange and maintain magnetic field symmetry.
Solution Approach 2:
The winding blade sections are made dynamically adjustable through pivoting mechanisms. The first and second sections can be pivoted by specific angles (e.g., 45° and 135°) relative to the third section to change winding directions. This dynamic adjustment ensures that conductors are wound in alternating directions in different sequences, preventing asymmetrical magnetic fields at layer transitions.
2Manufacturing precision
If the winding blade is designed with multiple pivotable sections, then control over winding direction is improved, but the complexity of the winding device increases
Solution Approach 1:
The winding blade is divided into multiple independent sections that can be pivoted separately. Each section is responsible for controlling the winding direction of specific sequences, allowing for precise control without requiring a completely complex redesign of the entire blade structure.
Solution Approach 2:
Different sections of the winding blade have different pivot angles and functions tailored to their specific roles. The first section pivots by a first angle to control one set of sequences, while the second section pivots by a second angle to control another set, optimizing each local region's function while maintaining overall system manageability.
3Ease of manufacture
If conventional winding methods are used, then manufacturing process is simple, but production costs remain high due to performance issues
Solution Approach 1:
The patent introduces dynamic pivoting of winding blade sections during the winding process. By pivoting the first and second sections relative to the third section, the winding direction can be changed mid-process to ensure alternating winding directions in different sequences. This maintains manufacturing feasibility while significantly improving magnetic field symmetry and machine performance.
Solution Approach 2:
The patent changes the winding direction parameter by pivoting specific sections of the winding blade. The first section is pivoted by a first angle and the second section by a second angle, creating alternating winding directions in different sequences. This parameter change prevents asymmetrical magnetic fields while maintaining a manufacturable process.
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 prevents unintentional interchanging of partial windings, achieving a symmetrical magnetic field and increasing the performance of electrical machines by ensuring consistent winding sequences, particularly at layer jumps, thereby enhancing the efficiency and reducing manufacturing costs.
Implementation Method 1
the conductors are heated to reduce stress during winding direction changes
Data Source
Figure 1~2
Figure 3~4
Figure 5~6C
AI summary
The invention relates to a method for producing an endless wave winding (10) for a stator 22 of an electrical machine, comprising the steps: - providing a winding blade (14), having a longitudinal axis 16, and with a first edge (18) and a second edge (20) arranged parallel to the longitudinal axis (16), the first edge (18) and the second edge (20) being spaced from one another; - providing a plurality of electrical conductors (12); - winding the electrical conductors (12) around the winding blade (14), wherein the electrical conductors (12) are deflected on and/or by the first edge (18) and the second edge (20), and a plurality of winding sequences are formed adjacent to one another in the longitudinal direction of the winding blade (14). In a winding sequence, the plurality of electrical conductors (12) are arranged adjacent to one another in the longitudinal direction of the winding blade (14). The plurality of winding sequences have at least a first sequence and a second sequence. In the first sequence, the plurality of the electrical conductors (12) are arranged adjacent to one another in a first order, and in the second sequence, - the plurality of electrical conductors (12) are arranged adjacent to one another in a second order which is at least in part different from the first order, or - the order of the electrical conductors (12) in the first sequence and in the second sequence is the same, wherein the winding direction of the first sequence around the winding blade (14) is different from the winding direction of the second sequence.