Flat Coil Bending Method for Linear Motor Resistance Reduction
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Solution Overview
Problem
In the manufacturing of coils for linear motors, the bent portions formed when flat coils are stacked and bent can increase in size, leading to higher resistance and heat generation, which deteriorates the coil's performance.
Innovation Solution
A method of manufacturing a coil where a level difference is created between the end faces of the first and second coil layers, allowing the flat coil to be bent with a smaller radius of curvature, reducing the size of the bent portions and minimizing resistance and heat generation, while also using an α-winding coil configuration to simplify wire connection and prevent tangling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the flat coil is bent toward the first coil layer from the second coil layer without a level difference, then the bending process is simpler, but the bent portion increases in size causing increased resistance and heat generation
Solution Approach 1:
A level difference is formed in advance between the end faces of the first and second coil layers before the bending process. Specifically, the end face of the second coil layer is positioned at a higher level than the end face of the first coil layer by a predetermined distance. This preliminary positioning ensures that when the flat coil is bent toward the first coil layer, the bent portion maintains a controlled, smaller size, thereby reducing resistance and heat generation while keeping the bending process manageable.
2Loss of energy
If the bent portion size is reduced by creating a level difference, then resistance and heat generation decrease, but the manufacturing process becomes more complex
Solution Approach 1:
The level difference is created during the coil winding process itself by controlling the positioning of the end faces of the first and second coil layers. This integrates the complexity into a single preparatory step rather than requiring additional post-processing operations, thereby minimizing the increase in manufacturing complexity while achieving the goal of reducing bent portion size and associated energy losses.
3Productivity
If the end portion of the conductive wire is not positioned carefully during bending, then the bending process is faster, but the wire becomes tangled with inner wires
Solution Approach 1:
The conductive wire's end portion is preliminarily positioned to extend from the outer peripheral side of the flat coil before the bending process begins. This preliminary positioning, combined with the pre-formed level difference between coil layers, ensures that during bending the wire naturally follows a clear path away from inner wires, preventing tangling and maintaining both high productivity and ease of wire connection operations.
Data Source
AI summary
A flat coil includes at least first and second coil layers having the shape of a ring and stacked, each of the first and second coil layers includes a pair of linear portions facing each other in a first direction and a pair of end portions facing each other in a second direction crossing the first direction, and the flat coil is bent on at least one of the end portions. The flat coil is an α-winding coil and is bent toward the first coil layer from the second coil layer. A first end face of the first coil layer in the second direction and a second end face of the second coil layer in the second direction are positioned on the same plane at the end portion to be bent.