Funnel-Shaped Silicon Steel Slots for Higher Circular Wire Fill
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Solution Overview
Problem
Conventional circular wire motors experience distortion and twisting of wires in the winding slot, leading to a low slot fill factor and compromised performance due to disorderly arrangement and large gaps between wires.
Innovation Solution
An annular silicon steel sheet with funnel-shaped open slots is used to form a winding slot, allowing circular wires to move towards the sides and reduce gaps, improving the slot fill factor and motor performance by arranging wires more regularly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional circular wire motors use standard winding slots, then the structure is simple, but the circular wires are prone to distortion and twisting, leading to large gaps and low slot fill factor
Solution Approach 1:
The patent applies asymmetry by designing the winding slot with a non-uniform cross-sectional shape that is wider at the opening and narrower at the bottom. This asymmetric geometry prevents circular wires from twisting and distorting by providing adequate space at the opening for wire placement while maintaining tight arrangement at the bottom, thereby improving wire arrangement regularity without requiring complex additional components
Solution Approach 2:
The patent utilizes curvature by designing the slot walls with specific curved profiles rather than straight lines. The curved slot walls better accommodate the circular cross-section of the wires, reducing stress concentration and preventing wire distortion. This curved geometry allows wires to be arranged more regularly along the slot bottom while maintaining structural simplicity
2Quantity of substance
If circular wires are placed in conventional winding slots, then the wiring process is simple, but the wires have large gaps and are arranged in disorder, reducing slot fill factor
Solution Approach 1:
The patent applies preliminary action by pre-designing the slot geometry with optimized dimensions and curved profiles before wire placement. The slot is prepared with sufficient width at the opening to facilitate easy wire insertion, while the narrowing toward the bottom pre-establishes the tight arrangement needed for high slot fill factor. This preliminary geometric preparation enables both easy operation and high wire density without requiring complex placement procedures
Solution Approach 2:
The patent applies local quality by varying the slot cross-sectional dimensions at different locations along its length. The opening region has larger dimensions to facilitate wire placement, while the bottom region has smaller dimensions to maximize wire density. This localized variation in slot geometry allows easy wire insertion at the opening while achieving high slot fill factor at the bottom where the wires are most densely packed
3Productivity
If standard winding slots are used, then the motor structure is simple, but the slot fill factor is low, affecting motor performance
Solution Approach 1:
The patent applies asymmetry by designing the winding slot with a non-uniform cross-sectional shape that is wider at the opening and narrower at the bottom. This asymmetric geometry prevents circular wires from twisting and distorting by providing adequate space at the opening for wire placement while maintaining tight arrangement at the bottom, thereby improving wire arrangement regularity without requiring complex additional components
Solution Approach 2:
The patent applies parameter changes by systematically varying the slot cross-sectional dimensions along its length. The slot width and height are adjusted at different positions to optimize wire arrangement - wider at the opening for accessibility, narrower at the bottom for density. This parameter optimization increases the slot fill factor and improves motor performance while maintaining a relatively simple overall structure
Data Source
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AI summary
Embodiments of this application provide an annular silicon steel sheet, a circular wire motor assembly, a circular wire motor, and a powertrain. The annular silicon steel sheet includes a plurality of open slots, each open slot penetrates the silicon steel sheet in an axial direction of the silicon steel sheet, and a projection of each open slot in the axial direction of the silicon steel sheet includes a first curve segment, a second curve segment, and a third curve segment. The first curve segment and the third curve segment are oppositely arranged in a circumferential direction of the silicon steel sheet, a bending direction of the first curve segment is away from a bending direction of the third curve segment, and a bending direction of the second curve segment is away from an opening of the open slot. The open slot in the annular silicon steel sheet is funnel-shaped, so that a winding slot in the circular wire motor assembly that is formed after a plurality of annular silicon steel sheets are adjacently arranged is funnel-shaped, thereby improving a slot fill factor of the circular wire motor, and further improving performance of the circular wire motor and the powertrain.