Concentrated Motor Windings With Lateral U-Wire Insertion
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Solution Overview
Problem
Conventional methods for manufacturing concentrated motor windings are slow and expensive, or fast but inefficient in terms of winding density, and they fail to provide improved electromagnetic and thermal performance.
Innovation Solution
The use of preformed U-shaped wires, which are bent, twisted, and welded together to form concentrated motor windings, allowing for higher winding density and efficient manufacturing processes, including lateral insertion onto stator poles rather than radial winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional radial winding methods are used, then manufacturing process is simple, but winding density is low (30-40% copper fill per slot area)
Solution Approach 1:
The wire is pre-formed into a U-shape with specific geometry before insertion, including predetermined bends and twists. This preliminary shaping enables the wire to be laterally inserted onto the stator pole and automatically form the desired winding configuration, achieving high winding density without complex assembly processes during manufacturing.
Solution Approach 2:
The invention transitions from conventional radial winding (inserting wire radially into slots) to lateral insertion (inserting wire laterally onto the stator pole face). This dimensional change in the insertion approach enables significantly higher copper fill density while simplifying the manufacturing process through automated placement.
2Productivity
If conventional winding methods are used, then manufacturing process is straightforward, but production speed is slow
Solution Approach 1:
The U-shaped wire is pre-formed with the exact geometry needed for the final winding configuration, including all bends and twists required. This eliminates time-consuming forming operations during assembly and enables rapid lateral insertion onto the stator pole, significantly increasing production speed.
Solution Approach 2:
The invention replaces complex mechanical winding operations with a simpler lateral insertion process. Pre-formed U-shaped wires are inserted laterally onto the stator pole face and secured, eliminating the need for time-consuming radial winding operations and enabling faster automated manufacturing.
3Reliability
If conventional winding methods are used, then manufacturing cost is lower, but electromagnetic performance is insufficient
Solution Approach 1:
The wire is pre-formed with optimized geometry including specific bend radii and twist configurations that maximize electromagnetic performance. This preliminary shaping ensures optimal magnetic field distribution and electrical characteristics while maintaining manufacturing simplicity through automated insertion processes.
Solution Approach 2:
The invention changes the geometric parameters of the wire configuration by using pre-formed U-shapes with specific dimensions, bend angles, and twist configurations. These parameter optimizations enhance electromagnetic performance including magnetic field distribution and thermal characteristics while the lateral insertion method maintains manufacturing simplicity.
4Temperature
If conventional winding methods are used, then thermal performance is inadequate, but manufacturing process is well-established
Solution Approach 1:
The transition to lateral insertion and pre-formed U-shaped wires creates superior thermal pathways. The three-dimensional configuration with optimized wire positioning improves heat dissipation from the winding to the stator pole and surrounding structures, enhancing thermal performance while the process remains manufacturable through automated techniques.
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 method enables faster, more efficient production of concentrated motor windings with increased copper fill per slot area, achieving a winding density of approximately 70% or greater, compared to conventional methods which achieve around 30-40%, while reducing manufacturing complexity.
Implementation Method 1
preformed U-shaped wires, which are bent, twisted, and welded together to form concentrated motor windings
Implementation Method 2
respective ends of the stacked wires may be welded together
Data Source
AI summary
Systems and methods to form concentrated motor windings may include bending wires into a U-shape, inserting the wires onto a stator pole, bending ends of the wires around the stator pole, and welding respective pairs of the ends of the bent wires. In some example embodiments, the U-shape may include a twist along a central portion thereof. In other example embodiments, a twist may be introduced along the respective pairs of bent ends of the wires that are then welded. In addition, the wires may be stacked and laterally inserted onto the stator pole. Further, the wire bending, twisting, insertion, welding, and other forming processes may be performed by automated or robotic machinery or equipment.