Multiphase Electromagnetic Mat Winding for Perpendicular Conductor Alignment
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Solution Overview
Problem
Existing methods fail to produce multiphase electromagnetic mats with conductors aligned perpendicular to the mat's length, resulting in expensive, suboptimal products, and lack scalable, flexible, and adjustable production methods for ironless and slotless components with high conductor fill factor.
Innovation Solution
A method and apparatus for producing multiphase electromagnetic mats with structural and winding fibers arranged perpendicularly, using movable magazines and transfer mechanisms to create continuous windings in a single layer, allowing for customizable and automated production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional winding methods on forms/mandrels are used, then electromagnetic mats can be produced, but the conductors are wound at an angle to the axis and require multiple layers, resulting in increased complexity and reduced efficiency
Solution Approach 1:
Instead of winding conductors around a form at an angle, the patent inverts the approach by laying conductors perpendicular to the axis of rotation and then rotating the entire assembly. This inversion achieves perpendicular conductor alignment (improving manufacturing precision) while eliminating the need for complex multi-layer winding structures (reducing device complexity).
Solution Approach 2:
The patent employs a cylindrical form with rotational symmetry, where conductors are laid perpendicular to the axis and the entire structure is rotated. This curved/rotational approach transforms the linear winding problem into a rotational assembly, achieving precise perpendicular conductor alignment while simplifying the overall winding structure through uniform curvature distribution.
2Ease of manufacture
If electromagnetic mats are produced as flat sheets requiring cutting and reconnecting, then production can be simplified, but additional steps are required resulting in expensive and suboptimal products
Solution Approach 1:
The patent enables continuous production of electromagnetic mats by winding conductors in uninterrupted patterns around the cylindrical form. The rotational mechanism allows continuous laying of conductors perpendicular to the axis without stopping for cutting or reconnecting, maintaining continuous useful action throughout the production process. This eliminates additional manufacturing steps while reducing production costs through improved efficiency.
3Quantity of substance
If conventional winding methods are used, then current carrying components can be produced, but the conductor fill factor is reduced and weight and compactness are compromised
Solution Approach 1:
By inverting the conventional winding approach and laying conductors perpendicular to the rotation axis rather than winding at an angle, the patent achieves superior conductor packing density. This inversion allows conductors to be arranged in a more space-efficient manner, increasing the conductor fill factor while reducing the overall volume and weight of the current carrying component.
Data Source
AI summary
A method and apparatus for production of a multiphase electromagnetic mat for forming current carrying components of a power conversion system, wherein the electromagnetic mat comprises structural fibre lengths divided into at least two groups and winding fibre lengths divided into several groups corresponding to the number of phases and the number of parallel conductors of one phase, wherein the winding fibre lengths are retained in position by the groups of structural fibre lengths.