Field Rotor Winding Layout to Prevent Wire Twisting Damage
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Solution Overview
Problem
Existing winding configurations for field windings in rotating electric machines require excessive twisting of conductor wires, leading to potential damage to the insulating coating and increased complexity due to the need for separate junction wires.
Innovation Solution
The field winding is configured with coil bodies wound in multiple layers around main pole portions, with inner and outer ends connected in series in the circumferential direction, minimizing radial twisting and simplifying the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the field winding is wound in multiple layers in the radial direction with series connections, then the winding process becomes simpler and productivity improves, but the conductor wire experiences reduced mechanical load and potential insulating coating damage
Solution Approach 1:
The field winding is divided into multiple coil bodies, each wound independently around individual main pole portions. This segmentation allows each coil body to be wound separately in multiple layers radially, simplifying the overall winding process while distributing mechanical stresses across discrete units rather than a continuous long wire
Solution Approach 2:
The patent transitions from traditional planar winding to three-dimensional multi-layer radial winding. By stacking conductor wires in multiple layers in the radial direction and connecting them systematically (inner ends to inner ends, outer ends to outer ends in series), the design optimizes space utilization and simplifies the winding operation while maintaining electrical continuity
2Reliability
If traditional field winding configurations are used, then the insulating coating may be damaged due to excessive twisting, but the winding process becomes more complex and requires separate junction wires
Solution Approach 1:
The patent merges the connection function into the winding structure itself. By systematically connecting inner ends to inner ends and outer ends to outer ends of adjacent coil bodies, the design eliminates the need for separate junction wires that would add complexity. The winding configuration inherently provides both the electrical connections and the mechanical support
Solution Approach 2:
Each coil body is pre-wound as a complete multi-layer unit around its main pole portion before installation. This preliminary action ensures that the insulating coating is not subjected to excessive twisting during the final assembly process, as the connections between coil bodies are made at predetermined locations (inner and outer ends) rather than requiring complex in-situ wiring
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 configuration reduces the load on conductor wires, prevents damage to the insulating coating, and allows for a simpler and more efficient winding process, improving productivity and space utilization.
Implementation Method 1
a field winding is wound around each main pole of a rotor core, and a field magnetic field is generated by passing current through the field winding
Data Source
AI summary
A winding field rotor includes a rotor core having main pole portions arranged in a circumferential direction and protruding in a radial direction, and a field winding. The field winding has coil bodies formed by winding a conductor wire in multiple layers in the radial direction for each of the main pole portions, and each of the coil bodies is connected in series in the circumferential direction. Each of the coil bodies has an inner end at a position on a radially inner side of the coil body, and an outer end at a position on a radially outer side of the coil body. The inner end is connected to the inner end of another coil body adjacent to the coil body on one circumferential side, and the outer end is connected to the outer end of another coil body adjacent to the coil body on the other circumferential side.