Flat-Wire Continuous Coil Winding for Higher Slot Fill Factor
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Solution Overview
Problem
Existing electric machine technologies face challenges in maximizing the slot fill factor, which limits the torque output and increases manufacturing complexity.
Innovation Solution
The development of a motor winding technique that uses a continuous, solid-core wire wound in a specific angular direction to form a continuous coil with high wire fill factor, achieved through a mandrel assembly with inward and outward helical ramps, allowing for maximal magnetic coupling and spatial efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional winding methods are used, then manufacturing process is simpler, but wire fill factor is lower and torque output is limited
Solution Approach 1:
The mandrel assembly is divided into multiple mandrels arranged in a circular array, each contributing to forming different portions of the continuous coil. This segmentation allows the complex winding task to be distributed across multiple simpler components, achieving high wire fill factor through coordinated action of multiple mandrels while keeping individual mandrel structures relatively simple
Solution Approach 2:
The mandrel assembly serves as an intermediary tool that temporarily holds and guides the wire during the winding process. By using this intermediate device with its specific helical ramp geometry, the system achieves precise wire placement and high spatial efficiency without requiring complex direct winding mechanisms
2Reliability
If wire is wound to maximize spatial efficiency, then magnetic coupling is improved, but manufacturing complexity increases
Solution Approach 1:
The mandrels are arranged in a circular array and the wire is wound in a continuous spiral path around them, creating a toroidal (doughnut-shaped) coil geometry. This curved, continuous winding pattern maximizes magnetic coupling by maintaining consistent spacing and optimal magnetic flux paths, while the modular circular arrangement of mandrels keeps the overall structure manageable
Solution Approach 2:
The continuous coil is wound in a nested spiral pattern around the circular array of mandrels, with each turn of the wire following a predictable path that maximizes space utilization. This nested arrangement ensures dense packing of wire turns while maintaining uniform magnetic properties, achieving high magnetic coupling without excessive structural complexity
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 approach results in a motor winding with a high wire fill factor, maximizing spatial efficiency and magnetic flux, thereby enhancing power density and torque output while simplifying the manufacturing process.
Implementation Method 1
a continuous coil wound from a single, continuous, solid-core wire... The coil winding assembly includes a first continuous coil wound in a first direction... The motor includes a rotor assembly surrounding the coil winding assembly and having a set of permanent magnets
Data Source
AI summary
A motor winding includes a wire defining a rectangular cross-section and wound in a continuous direction about a coil axis to form a continuous coil including: a first coil segment spiraling in a first plane, defining a first external terminal, and defining a first interior end inset from the first external terminal and arranged on a first side of a coil axis; a second coil segment spiraling in a second plane parallel and offset from the first plane, defining a second exterior terminal parallel to the first external terminal, and defining a second interior end inset from the second exterior coil end and arranged on a second side of the coil axis opposite the first interior end; and a junction extending between the first plane and the second plane to couple the first interior end of the first coil segment to the second interior end of the second coil segment.