3D PCB Winding with Vertical Shortcuts for Electrical Machines
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Solution Overview
Problem
Existing electrical machine windings suffer from inefficiencies due to high electrical resistance, leading to losses and suboptimal torque or force density, which are not adequately addressed by current designs.
Innovation Solution
A modified winding structure with multiple layers of conductors and strategic shortcut connections, including vertical and horizontal shortcuts, is introduced to minimize electrical resistance while maximizing magnetic flux interception, thereby improving efficiency and torque or force density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional copper-wire winding is used, then the structure is simple and easy to manufacture, but the electrical resistance is high leading to energy losses
Solution Approach 1:
The patent transitions from traditional 2D planar winding layouts to a 3D multi-layer PCB winding structure. Conductors are arranged in multiple layers separated by intermediate insulating layers, with vertical shortcut connections enabling three-dimensional current paths. This dimensional expansion reduces conductor length and electrical resistance while maintaining manufacturing simplicity through PCB fabrication techniques.
Solution Approach 2:
The winding is segmented into multiple independent conductor layers, each performing specific functions. First conductors in a first layer and second conductors in a second layer are separated by intermediate layers, with selective connections between layers. This segmentation allows optimization of current paths in each layer, reducing overall electrical resistance and improving energy efficiency.
2Loss of energy
If conductor length is reduced to minimize resistance, then efficiency improves, but the ability to intercept magnetic flux may be compromised
Solution Approach 1:
By utilizing multiple layers separated by intermediate layers with vertical shortcut connections, the winding achieves compact 3D current paths that minimize conductor length and resistance. The multi-layer structure maintains effective magnetic flux interception by positioning conductors optimally within the magnetic field region, with first and second conductors forming turns that intercept radial or axial flux components.
Solution Approach 2:
Different regions of the winding are optimized for different functions. First conductors and second conductors are positioned to intercept magnetic flux effectively, while vertical shortcut connections provide low-resistance return paths. The intermediate layers are strategically placed to enable compact folding of the winding without compromising flux interception in critical regions.
3Productivity
If multiple layers with shortcut connections are added to reduce resistance, then efficiency and torque density improve, but manufacturing complexity increases
Solution Approach 1:
The patent replaces traditional mechanical winding processes with PCB fabrication techniques. Conductors are formed as printed circuit traces on PCB substrates, with intermediate layers serving as PCB insulation. This substitution enables precise conductor positioning, consistent trace widths for controlled resistance, and automated manufacturing through standard PCB processes, reducing both complexity and cost despite the multi-layer structure.
4Loss of energy
If conductor paths are optimized for minimal resistance, then efficiency improves, but the winding structure becomes more complex
Solution Approach 1:
The patent uses vertical shortcut connections through intermediate layers to create three-dimensional current paths that minimize total conductor length. First conductors in the first layer connect to second conductors in the second layer via vertical shortcuts, enabling compact return paths that reduce resistance without requiring complex lateral routing. This vertical dimension simplifies the overall conductor arrangement compared to traditional planar layouts.
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
The proposed winding design achieves a 15% improvement in torque or force density and reduced electrical resistance, enhancing the overall performance of electrical machines by optimizing the interaction with the magnetic field.
Implementation Method 1
each pair of conductors forming a turn intercepting a fraction of the magnetic field
Implementation Method 2
said first and second layers being separated by an intermediate layer, said intermediate layer having an height perpendicular to said length
Data Source
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AI summary
Winding for an electrical machine having an inductor with pole pitch τp, having a plurality of groups of turns intercepting a fraction of a magnetic field, each group comprising a first subgroup of turns and a second subgroup of turns of same phase at a distance equal to τp, the turns of the first subgroup being connected in such a way that a current may flow in same direction in all turns of said subgroup, the turns of the second subgroup being connected in such a way that a current may flow in same direction in all turns of said subgroup, a turn of the first subgroup being connected to a turn of the second subgroup in such a way that the direction of said current in the first group is opposite to the direction of the current in the second subgroup. According to the invention, the winding is a wave winding comprising vertical shortcut connections.