Field Winding Layout for Higher Space Factor in Rotating Machines
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Solution Overview
Problem
Conventional field winding type rotating electric machines have a low space factor for the field winding, which limits their exciting characteristic and efficiency.
Innovation Solution
The field winding type rotating electric machine increases the space factor by arranging rectangular wires in both radial and circumferential directions, with inclined portions at the outer ends of the windings, and using press molding to improve assembly and insulation between adjacent windings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional field winding arrangement is used, then the structure is simple, but the space factor is low
Solution Approach 1:
The patent applies dimensional change by arranging rectangular wires in both radial and circumferential directions, transitioning from conventional single-direction winding to two-dimensional arrangement. This allows the field winding to fully utilize the main pole portion space, increasing the space factor from conventional levels to 70% or more, while the press molding process integrates multiple functions into a unified manufacturing step.
Solution Approach 2:
The patent implements nesting by placing multiple rectangular wires in layers within the main pole portion, with each wire nested alongside others in both radial and circumferential directions. This nested arrangement maximizes space utilization, allowing the field winding to occupy 70% or more of the available space while maintaining structured organization through the press molding process.
2Reliability
If field winding space factor is increased, then exciting characteristic improves, but manufacturing difficulty increases
Solution Approach 1:
The patent applies preliminary action by pre-arranging rectangular wires in the desired two-dimensional configuration before final assembly into the main pole portion. The press molding process performs preliminary compression and positioning of the wires, ensuring proper arrangement in both radial and circumferential directions before the winding is permanently installed, thereby facilitating easier manufacturing despite the complex spatial arrangement.
Solution Approach 2:
The patent utilizes parameter changes by transforming the physical state of the field winding through press molding, which applies controlled pressure to compress and shape the rectangular wires into the target configuration. This parameter change from loose arrangement to compressed structured arrangement enables the achievement of 70% or more space factor while maintaining manufacturing feasibility through standardized pressing operations.
3Ease of manufacture
If press molding is used, then assembly and insulation improve, but manufacturing process complexity increases
Solution Approach 1:
The patent applies merging by combining multiple manufacturing functions into the single press molding process. This unified operation simultaneously achieves wire compression, spatial arrangement in two directions, electrical insulation positioning, and structural consolidation, thereby improving assembly and insulation quality while avoiding the need for multiple separate manufacturing steps that would increase overall process complexity.
Solution Approach 2:
The press molding device is designed with multi-functionality, serving as a universal tool that performs compression, shaping, insulation positioning, and structural consolidation in a single operation. This universal device handles multiple manufacturing requirements simultaneously, improving assembly and insulation quality without proportionally increasing process complexity, as one device accomplishes what would otherwise require multiple specialized operations.
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 enhances the space factor, reduces resistance and losses, and improves the exciting characteristic of the field winding, while providing effective electrical insulation and improved manufacturing efficiency.
Implementation Method 1
using press molding to improve assembly and insulation between adjacent windings
Data Source
AI summary
A rotating electric machine includes a rotor, main pole portions, and a field winding. A center axis of the main pole portion extending in a radial direction passing through a rotation center axis of the rotor is defined as a first axis, an axis passing through a center position of the first axis adjacent in the circumferential direction and a rotation center axis and extending in a radial direction is defined as a second axis, and an axis passing through a center position of the first axis and the second axis that are adjacent in the circumferential direction and the rotation center axis and extending in the radial direction is defined as a third axis. An outer end portion of the field winding in the circumferential direction in each of the main pole portions is positioned between the second axis and the third axis in the circumferential direction.