Polygonal Cross-Section Motor Coil Insulation Design
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Solution Overview
Problem
Existing motor coils with rectangular cross-sections face challenges in maintaining insulation between neighboring turns, leading to potential insulation damage and loss, which affects motor efficiency and reliability.
Innovation Solution
A coil with a polygonal cross-section and a spiral winding configuration, where insulating members are strategically placed on the upper or lower surfaces of the turns to maintain a predetermined gap and ensure insulation between turns, using a conductive wire with a rectangular cross-section and an insulating layer to prevent contact between turns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cast coils with rectangular cross-section are used to improve space factor, then heat dissipation efficiency is improved, but insulation between neighboring turns may be lost due to insulating film damage
Solution Approach 1:
The insulating member is divided into a first insulating portion and a second insulating portion that are disposed at different positions (upper surface and lower surface of turns) to provide comprehensive insulation coverage while maintaining the rectangular coil structure for heat dissipation
Solution Approach 2:
The insulating member acts as an intermediary component between neighboring turns, providing physical separation and insulation without interfering with the rectangular coil structure's heat dissipation function
2Reliability
If insulating members are added to maintain insulation between turns, then reliability is improved, but device complexity increases
Solution Approach 1:
The first insulating portion and second insulating portion of the insulating member are integrated into a single component that performs multiple insulation functions simultaneously, reducing the number of separate parts needed
Solution Approach 2:
The insulating member is designed to perform multiple functions: providing insulation between turns, maintaining the gap between neighboring turns, and being disposed at specific positions to prevent insulating film damage, all within a single component
Data Source
AI summary
A coil includes: a series of turns constituted by a first turn to an n-th turn of a conductive wire having a polygonal cross-section, where n is an integer equal to or larger than 3, and the conductive wire is wound in a spiral shape and is stacked in a direction from downward toward upward; and an insulating member disposed on either an upper surface or a lower surface of an i-th turn, where i is an integer satisfying 1≤i≤n.