Electric Motor Winding Space Extension for Slot Fill Factor
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Solution Overview
Problem
Existing electric motors face inefficiencies due to coil windings slipping during the winding process, leading to suboptimal utilization of available space in the winding areas and low slot filling factors.
Innovation Solution
The design incorporates second winding chambers with opposing receiving pockets on the rotor and/or stator, which securely hold wire sections in place, allowing for optimal space utilization and high slot fill factors by preventing slippage during the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional winding spaces are used without extensions, then the structure is simple, but the slot filling factor is reduced due to wire slippage
Solution Approach 1:
The winding space is segmented into a primary winding space and an extension winding space. The extension winding space is divided into multiple receiving pockets that are circumferentially spaced, allowing the wire to be secured at multiple positions along its length. This segmentation prevents wire slippage while maintaining a manageable structural complexity through modular design.
Solution Approach 2:
The extension winding space extends the traditional winding space in the radial direction, creating additional dimensional space for securing the wire. By adding receiving pockets at different radial positions and circumferential spacings, the solution utilizes three-dimensional space more effectively to prevent wire slippage without significantly increasing overall structural complexity.
2Volume of stationary object
If wire sections are allowed to slip in winding spaces, then the winding process is simpler, but the available space cannot be optimally utilized
Solution Approach 1:
The receiving pockets are pre-formed in the extension winding space at specific circumferential spacings and radial positions. During the winding process, wire sections are automatically positioned and secured in these pre-prepared pockets, eliminating the need for complex real-time adjustments. This preliminary preparation of securing positions maximizes space utilization while keeping the winding process relatively simple.
3Reliability
If receiving pockets are added to secure wire sections, then wire slippage is prevented, but the device complexity increases
Solution Approach 1:
Instead of uniformly complexifying the entire winding space structure, receiving pockets are strategically placed only in specific regions where wire slippage is most likely to occur. The pockets are positioned at specific circumferential spacings and radial depths, providing localized quality enhancement exactly where needed to prevent slippage, while leaving other areas of the winding space relatively simple.
Data Source
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AI summary
The invention relates to an electric motor with a rotor and a stator (1), wherein the rotor and/or the stator (1) is formed as a first winding space (11) for receiving a plurality of coil windings (12) wound from a winding wire and a second winding space (20) connected to the respective first winding space (11) as a winding space extension of the first winding space (11) for receiving at least one wire section (21) of the winding wire, wherein in the second winding space (20) two receiving pockets (24, 25) opposite each other in the circumferential direction (U) are formed for receiving the at least one wire section (21) of the winding wire.