Rotating Electric Machine Fusion Layer Conductor
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Solution Overview
Problem
Conventional rotating electric machines with stator windings face challenges in manufacturing complexity and space factor due to thick insulation coatings, leading to increased eddy current losses and difficulty in maintaining the bundled wire configuration.
Innovation Solution
The rotating electric machine employs a conductor winding with a fusion layer that is thinner than the insulation coating, eliminating the need for an additional insulating layer and allowing the fusion layers to fuse and contact each other, while having a different coefficient of linear expansion than the insulation coating to manage thermal stress and maintain the bundled configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thick insulation coating is applied to bundled wires in the armature winding, then electrical insulation is improved, but the space factor of the conductor body decreases and manufacturing complexity increases
Solution Approach 1:
The patent merges the insulation coating and fusion layer into a single integrated structure. The insulation coating serves dual purposes: providing electrical insulation and acting as the fusion layer that bonds adjacent wires together. This eliminates the need for separate insulation and bonding layers, thereby improving space factor while maintaining electrical insulation reliability.
Solution Approach 2:
The insulation coating is designed to perform multiple functions simultaneously: electrical insulation, mechanical bonding (fusion), and structural support. By making the insulation coating universally functional, the patent reduces the number of separate components needed, thus improving space factor without compromising insulation performance.
2Stability of the object's composition
If a thick insulation coating is used to maintain bundled wire configuration, then structural stability is improved, but manufacturing complexity and difficulty increase
Solution Approach 1:
The patent combines the insulation coating and fusion layer into one integrated component. This merger simplifies the manufacturing process by reducing the number of separate layers that need to be applied and bonded, while still maintaining the structural stability of the bundled wire configuration through the multi-functional insulation coating.
Solution Approach 2:
The insulation coating is designed to provide both electrical insulation and mechanical bonding functions in a single layer. This multi-functionality reduces manufacturing complexity by eliminating the need for separate fusion layers, while still ensuring the bundled wire configuration remains stable during operation.
3Reliability
If the fusion layer has the same coefficient of linear expansion as the insulation coating, then material compatibility is improved, but thermal stress management deteriorates
Solution Approach 1:
The patent changes the physical parameters of the insulation coating by creating a multi-layer structure with different coefficients of linear expansion. The fusion layer has a higher coefficient of linear expansion than the insulation coating, allowing each layer to expand at different rates during thermal cycling. This parameter differentiation enables effective thermal stress management while maintaining material compatibility through proper interface design.
Solution Approach 2:
The patent uses a composite structure consisting of the insulation coating and fusion layer with different material properties. The fusion layer is made of a material with a higher coefficient of linear expansion than the insulation coating, creating a composite material system that can better accommodate thermal expansion differences and reduce thermal stress concentration.
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 design simplifies manufacturing, reduces eddy current losses, and improves the space factor of the conductor body by eliminating the need for an additional insulating layer and effectively managing thermal expansion.
Implementation Method 1
a coefficient of linear expansion of the fusion layer differs from a coefficient of linear expansion of the insulation coating
Data Source
AI summary
A rotating electric machine includes an armature that has an armature winding of multiple phases. The armature winding is configured by a conductor being wound. The conductor is configured by a plurality of wires covered by an insulation coating in a state in which the plurality of wires are bundled. Each of the plurality of wires includes a conductor body configured to permit flow of a current, and a fusion layer that covers a surface of the conductor body. The fusion layer is configured to be thinner than the insulation coating. In the state in which the plurality of wires are bundled, fusion layers of the plurality of wires are fused and in contact with one another. A coefficient of linear expansion of the fusion layer differs from a coefficient of linear expansion of the insulation coating.