Galvanometer-Based Turn Count Testing for Concentrated Winding Stators
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Solution Overview
Problem
Manual winding of electrical machine stators with concentrated winding makes it difficult to control and accurately test the number of turns, leading to inconsistencies during the fabrication process.
Innovation Solution
An apparatus comprising a base, a rod-shaped rotor bracket with an excitation coil and a standard coil, a joining member for relative rotation, and a galvanometer connected in series to form a loop with the test coil, allowing for direct testing of the number of turns by observing the galvanometer's deflection when energized by alternating current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual winding is used for concentrated winding stators, then flexibility in prototyping is improved, but manufacturing precision of the number of turns deteriorates
Solution Approach 1:
The patent introduces a testing apparatus as an intermediary device between the manual winding process and quality control. The apparatus includes a galvanometer, excitation coil, and magnetic circuit that serve as mediating components to objectively measure and verify the number of turns in wound coils, bridging the gap between manual operation and precision requirements
Solution Approach 2:
The testing apparatus provides immediate feedback through the galvanometer reading, allowing operators to verify the number of turns right after winding. This feedback mechanism enables real-time quality control, where the galvanometer's deflection indicates whether the coil meets the specified turn count, allowing for corrective action before proceeding to the next coil
2Device complexity
If traditional testing methods are used, then device complexity is reduced, but measurement precision of the number of turns deteriorates
Solution Approach 1:
The patent extracts the essential measurement function from complex automated winding machines and creates a standalone, simple testing apparatus. By separating the testing function into an independent device with minimal components (galvanometer, excitation coil, yokes), it achieves precise measurement without the complexity of integrated automated systems
Solution Approach 2:
The patent replaces complex mechanical counting mechanisms with an electromagnetic measurement system. Instead of using mechanical devices to count and verify turns, the invention uses electromagnetic induction principles where the galvanometer measures the induced current proportional to the number of turns, substituting a simple electromagnetic measurement for complex mechanical counting
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
The apparatus enables precise and straightforward testing of the number of turns in each coil, ensuring accuracy and simplicity in the fabrication process of electrical machines with concentrated winding.
Implementation Method 1
an excitation coil and a standard coil, a joining member for joining the base with the rotor bracket so that the base and the rotor bracket can rotate relative to each other... the excitation coil on the rotor bracket is energized by an alternating current
Implementation Method 2
a galvanometer connected to the standard coil, which is connected to the coil of the electrical machine stator with concentrated winding under test in reverse polarity to form a loop during testing
Data Source
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AI summary
An apparatus for testing number of turns, used for testing the number of turns of a winding coil on an electrical machine stator with concentrated winding, comprising: a base (6); a rod-shaped rotor bracket (4) around one end of which an excitation coil (1) is wound and around the other end of which a standard coil (2) is wound; a joining member for joining the base (6) with the rotor bracket (4) so that the base (6) and the rotor bracket (4) can rotate relative to each other, wherein the plane of the base (6) is parallel to the rotor bracket (4); a fixing member for fixing the electrical machine stator (5) with concentrated winding to the base (6) so as to make the stator (5) concentric and coplanar with the rotor bracket (4); a galvanometer (17) connected to the standard coil (2), which is connected to the tested coil (3) of the stator (5) in reverse polarity to form a loop during testing. Also provided is a method for using the apparatus to test the number of turns. The apparatus for testing number of turns has a simple structure, is of great utility and can test the number of turns of a winding coil on an electrical machine stator with concentrated winding directly.