MSO Coil Manufacturing Using Bent Unit Layers
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Solution Overview
Problem
Conventional methods for manufacturing MSO coils face challenges in achieving high coil space factor, uniform electric resistance, low heat generation, and efficient assembly with rotor and stator, while also being cost-effective and time-efficient, due to limitations in winding techniques and machining methods.
Innovation Solution
A method involving a pressing step to form a bent surface on unit coil layers, a fixing step to connect these layers with a coupling structure using grooves and protrusions, and a bonding step using resistance heat to integrate the connections, along with a device comprising press jigs and welding machines to support and bond the coil layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional winding methods are used to manufacture MSO coils, then the manufacturing process is simple, but the coil space factor is low and uniformity of current density is poor
Solution Approach 1:
The coil is divided into multiple coil layers with standardized cross-sectional shapes that can be manufactured separately and then assembled. Each coil layer has a consistent geometry that optimizes space utilization, and the segmentation allows for precise manufacturing of each layer before final assembly into the complete MSO coil structure.
Solution Approach 2:
The invention transitions from conventional two-dimensional winding to a three-dimensional stacked structure where multiple coil layers are arranged in specific spatial configurations. This dimensional change enables better space utilization and uniform current density distribution by optimizing the vertical and horizontal arrangement of coil layers.
2Manufacturing precision
If electro discharge machining and mechanical machining methods are used to manufacture MSO coils, then the coil shape precision is improved, but the productivity is low and unit cost is high
Solution Approach 1:
Coil layers are pre-manufactured with precise geometries using standardized processes, and then pre-assembled into complete MSO coils before final installation. This preliminary preparation of components allows for higher precision manufacturing of individual parts while maintaining overall productivity through efficient assembly operations.
Solution Approach 2:
The invention changes the manufacturing parameters from traditional machining operations to a combination of precision forming and automated assembly processes. By optimizing parameters such as coil layer thickness, spacing, and arrangement patterns, the system achieves high precision while improving manufacturing speed and reducing costs.
3Power
If the diameter of the coil is increased to improve efficiency, then the output is increased, but the space factor is lowered due to waste space between wound coil layers
Solution Approach 1:
The coil layers are designed with optimized curved cross-sectional shapes that better fit the available space in the motor stator or rotor. This curvature optimization eliminates waste spaces between coil layers while maintaining the required electrical performance and motor output.
Solution Approach 2:
The invention uses standardized, repeatable coil layer designs that can be copied and stacked multiple times to build up the complete coil structure. This copying approach ensures consistent space utilization across all coil layers and allows for scalable manufacturing while maintaining high space factors.
4Quantity of substance
If the diameter of the coil is decreased to improve space factor, then the space utilization is improved, but the electrical resistance increases causing efficiency reduction and heat generation
Solution Approach 1:
The coil structure is designed with locally optimized properties where the cross-sectional shape and dimensions of each coil layer are tailored to achieve uniform current density distribution. This local quality optimization ensures that electrical resistance is minimized in critical areas while maintaining high overall space factor.
Solution Approach 2:
The invention employs composite coil structures combining different materials or configurations within the coil layers to simultaneously achieve low electrical resistance and high space factor. The composite design allows for optimized electrical pathways while efficiently utilizing the available space.
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 approach enables the production of MSO coils with higher production speeds and lower costs compared to traditional methods, ensuring uniform electric resistance and efficient assembly, while minimizing waste space and heat generation.
Implementation Method 1
a bonding step of bonding connection parts where one end and the other end of each of a plurality of unit coil layers that are connected and fixed to each other are in contact
Data Source
AI summary
Disclosed is a method for manufacturing an MSO coil, comprising: a pressing step of forming a bent surface on a part of a unit coil layer, which has a ring shape such that both ends thereof face each other, thereby endowing both ends of the unit coil layer with a height difference; a fixing step of connecting and fixing a plurality of unit coil layers to each other, each unit coil layer having the bent surface formed thereon, such that the first end of both ends of a unit coil layer having the bent surface formed thereon contacts the second end of both ends of another unit coil layer having the bent surface formed thereon; and a bonding step of bonding connection parts defined by contact of the first and second ends of each of the plurality of unit coil layers that are connected and fixed to each other.