Multiphase Electromagnetic Mat Layout for Transverse Windings

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Solution Overview

Problem

Existing methods fail to produce multiphase electromagnetic mats with conductors aligned perpendicular to the length of the mat, resulting in expensive, suboptimal products that require additional cutting and reconnecting steps, lack scalability and flexibility, and do not achieve high conductor fill factor for low weight and compactness.

Innovation Solution

A method and apparatus for producing multiphase electromagnetic mats with structural fibers aligned along the mat's length and winding fibers transversely, using movable magazines and a transfer mechanism to create continuous, multiple-phase windings with adjustable patterns, enabling flexible and scalable production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional winding methods are used on forms/mandrels, then windings can be created, but additional cutting and reconnecting steps are required resulting in expensive and suboptimal products

Engineering Contradiction:

Improveproduction process simplicityVSAvoidadditional cutting and reconnecting steps

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The electromagnetic mat is divided into multiple segments that can be produced separately and then assembled. Each segment contains a portion of the winding pattern, allowing continuous windings to be created without cutting and reconnecting entire windings. This segmentation enables modular production while maintaining winding continuity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The winding pattern is pre-established on the mat before the mat is cut into segments. By creating the complete continuous winding pattern first and then segmenting the mat, the invention eliminates the need for cutting and reconnecting windings during assembly. The preliminary winding creation ensures continuity is maintained across segments.

Inventive Principle:

Principle #10Preliminary action

2Quantity of substance

If electromagnetic mats are produced as flat sheets requiring cutting and reconnecting, then production can proceed, but conductor fill factor is reduced and weight increases

Engineering Contradiction:

Improveconductor fill factorVSAvoidcomponent weight

Core Design Contradiction:

Quantity of substanceVSWeight of moving object

Solution Approach 1:

The mat is segmented after the complete winding pattern is established, allowing optimal conductor arrangement without waste. The segmentation enables precise placement of conductors in the required patterns while minimizing unused space, thereby increasing conductor fill factor and reducing overall weight.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the production approach from creating complete windings on forms to creating flat sheets with pre-established winding patterns. This parameter change in the manufacturing method allows for higher conductor density and better space utilization, increasing fill factor while reducing weight.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If conventional production methods are used, then electromagnetic mats can be produced, but scalability and flexibility are limited

Engineering Contradiction:

Improveproduction volumeVSAvoidcustomization capability

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

Segmenting the mat into modular units enables scalable production. Multiple segments can be produced in parallel and assembled to create larger systems, increasing productivity. The modular nature also allows easy customization by selecting and assembling different segment combinations for various applications.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The segmented mat design creates universal components that can be used in multiple configurations and applications. The same segment types can be assembled in different patterns to create various electromagnetic mat sizes and specifications, providing both scalability and flexibility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Strength

If conductors are wound at an angle to the cylinder axis with multiple layers, then windings can be created, but the structure becomes complex and weight increases

Engineering Contradiction:

Improvewinding structure integrityVSAvoidwinding weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

Instead of winding conductors around a cylinder at angles to create multi-layer structures, the invention inverts the approach by creating flat sheets with winding patterns already established on the surface. This eliminates the need for complex angled winding and multiple layers, reducing weight while maintaining structural integrity through the flat mat design.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentEP4147334B1Method and apparatus for production of a multiphase electromagnetic mat for forming current carrying components of a power conversion system

Publication Date: 2025.09.03 ALVA IND AS

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Figure 4(a)~4(e)

AI summary

The present invention provides a method and apparatus forproduction of a multiphase electromagnetic mat (10) for forming current carrying components of a power conversion system, wherein the electromagnetic mat (10) comprises structural fibre lengths (20)divided into at least two groups (21, 22) and winding fibre lengths(71A, 71B) divided into several groups corresponding to the number of phases and the number of parallel conductors of one phase,wherein the winding fibre lengths (71A, 71B) are retained in position by the groups (21, 22) of structural fibre lengths (20).