Miniature Motor Winding Segmentation for Commutator Welding
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Solution Overview
Problem
Conventional 4-pole field DC miniature motors face challenges in continuous winding and connection of short circuit wires, leading to nonuniform winding resistance and unstable performance due to bulky gathering of thick electric wires near commutator segments, which complicates spot welding and increases motor length.
Innovation Solution
A miniature motor design where magnets are mounted alternately on the motor casing, with an even number of rotor poles and commutator segments, using salient magnetic pole cores for windings connected to commutator segments, and employing first-type and second-type windings with only one short circuit wire connecting radially opposed commutator segments, reducing the number of electric wires hooked to two or less.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple thick electric wires are hooked to commutator segments for continuous winding, then continuous winding and connection of short circuit wires is achieved, but the electric wires gather bulkily near commutator segments making spot welding difficult and increasing motor length
Solution Approach 1:
The patent divides the winding structure into two types: first-type windings connected to adjacent commutator segments and second-type windings connected to radially opposite commutator segments. This segmentation allows only one short circuit wire per radially opposite commutator segment pair, reducing wire gathering bulk and facilitating spot welding while maintaining continuous winding capability.
Solution Approach 2:
The patent introduces a radial dimension to the winding configuration by connecting windings to radially opposite commutator segments. This dimensional change allows the winding structure to distribute wires more evenly in the radial direction rather than concentrating them at single locations, reducing bulk and improving weldability.
2Productivity
If multiple thick electric wires are hooked to commutator segments for continuous winding, then continuous winding and connection of short circuit wires is achieved, but motor length increases
Solution Approach 1:
By segmenting the winding into first-type and second-type configurations, the patent reduces the number of short circuit wires needed to connect radially opposite commutator segments from multiple wires to just one wire per segment pair. This reduction eliminates unnecessary wire length and motor housing space requirements.
Solution Approach 2:
The patent extracts and eliminates redundant short circuit wires from the conventional winding structure. By recognizing that only one short circuit wire is needed per radially opposite commutator segment pair, the design removes excess wires that would otherwise increase motor length.
3Productivity
If multiple thick electric wires are hooked to commutator segments, then continuous winding is achieved, but winding resistance becomes nonuniform and performance becomes unstable
Solution Approach 1:
The patent segments the winding structure into first-type windings (connecting adjacent segments) and second-type windings (connecting radially opposite segments). This segmentation creates a more balanced and uniform current distribution path, reducing variations in winding resistance and improving performance stability.
Solution Approach 2:
The patent applies different winding connection patterns at different locations: first-type windings connect adjacent commutator segments while second-type windings connect radially opposite segments. This localized differentiation optimizes current distribution and reduces resistance nonuniformity throughout the motor structure.
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 configuration allows for continuous winding with improved performance by stabilizing current flow and reducing nonuniformity in winding resistance, avoiding the issues of bulky wire gathering and motor length increase.
Implementation Method 1
magnets are mounted on an inner circumferential surface of a motor casing in such a manner that their N and S poles are alternatingly inverted, so as to serve as field magnets
Implementation Method 2
each of the rotor poles has a salient magnetic pole core and a winding wound about a single salient magnetic pole core or a plurality of salient magnetic pole cores
Data Source
AI summary
A type-A winding represented by a triangle of solid lines is connected to commutator segments such that its one end is connected to an arbitrary commutator segment and its other end is connected to a commutator segment adjacent to the arbitrary commutator segment. A type-B winding represented by a diamond of broken lines is connected to commutator segments such that its one end is connected to a commutator segment located radially opposite to a usual adjacent commutator segment. The type-A windings and the type-B windings are used in combination. One short circuit wire is used for every short circuit connection of radially opposed commutator segments. A total number of the short circuit wires is half (5) the number (10) of commutator segments. Thus, the number of electric wires hooked at every commutator segment can be reduced to two or less. Also, continuous winding by use of one or two wires is possible.