Integral Coil Element Layout for Compact Axial Windings
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Solution Overview
Problem
Existing electric machine windings require significant installation space, particularly in the axial direction, and are complex to produce, leading to inefficiencies and high losses.
Innovation Solution
A coil element design with integrally formed conductor elements and connection portions that minimize axial installation space by using straight-line connections and S-shaped configurations, along with varying winding steps and symmetrical arrangements to optimize space and reduce stress on insulating coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional turn regions with bending positions are used to connect conductor elements, then the coil element can be formed integrally, but the axial installation space is increased
Solution Approach 1:
The connection portion is configured to extend primarily in the radial direction rather than the axial direction. By changing the orientation of the connection from axial to radial, the patent reduces the axial installation space while maintaining integral formation of the coil element. The bending positions are arranged such that the connection portion extends in a direction perpendicular to the axial direction, effectively utilizing the radial dimension to resolve the space constraint.
2Device complexity
If bending positions are concentrated in a single location to connect conductor elements, then the coil element structure is simplified, but the stress on insulating coating is increased
Solution Approach 1:
The bending position is divided into multiple partial bending positions (first, second, third partial bending positions) arranged sequentially along the connection portion. This segmentation distributes the bending stress across multiple locations rather than concentrating it in a single point, thereby reducing the stress on the insulating coating at any one location while maintaining the overall simplified structure of the coil element.
Solution Approach 2:
The connection portion is configured with a curved or bent geometry rather than a straight line, creating a smooth transition between conductor elements. This curved configuration distributes the stress more evenly along the connection portion and reduces stress concentration at any single point, protecting the insulating coating from damage while maintaining structural integrity.
3Length of stationary object
If connection portions are arranged to minimize axial space, then the coil head becomes more compact, but the production complexity increases
Solution Approach 1:
The connection portion is configured with an asymmetric arrangement of bending positions that optimizes the radial and circumferential layout rather than maintaining symmetric axial alignment. This asymmetric configuration allows the connection portions of different coil elements to be arranged more efficiently in the radial direction, reducing axial space while the regular pattern of partial bending positions maintains production simplicity through repetition.
Solution Approach 2:
The coil elements are pre-formed with the connection portions and bending positions already configured during manufacturing, rather than being assembled from separate components. This preliminary formation of the complete coil element structure, including the optimized radial arrangement of connection portions, simplifies the final assembly process while achieving the compact axial configuration.
Data Source
AI summary
A coil element for a coil of an electric machine having at least two conductor elements extending parallel for arrangement in slots of a coil body and at least one connection portion that connects the two conductor elements to one another. The conductor elements and the connection portion are integrally formed. A bending position in a plane defined by the two conductor elements is provided only at a transition from a conductor element to the connection portion, and the connection portion extends in a straight line.