Polygonal Rotor Winding Layout for Balanced Motor Assemblies
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Solution Overview
Problem
Current rotor winding methods, such as sequential and symmetrical winding, result in uneven weight distribution, dynamic unbalance, and low rotor winding efficiency due to inconsistent resistances and suboptimal space utilization in the slot.
Innovation Solution
A rotor assembly with a rotor winding that extends in both axial and perpendicular directions, forming sections corresponding to the sides of polygons, ensuring uniform mass distribution and consistent resistances by eliminating overlaps and optimizing the winding pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sequential winding using single-flying-fork is used, then the winding process is simple, but the weight distribution of the armature is not uniform resulting in large dynamic unbalance
Solution Approach 1:
The rotor winding is divided into multiple independent coils, each coil being wound separately and then assembled into the rotor slots. This segmentation allows each coil to be precisely controlled for weight and dimensions, while the overall assembly achieves uniform weight distribution through systematic arrangement of the segmented coils around the rotor periphery.
2Manufacturing precision
If symmetrical winding using twin-flying-fork is used, then the weight distribution can be improved, but the rotor winding efficiency is very low
Solution Approach 1:
Coils are pre-wound and pre-assembled into coil sets before being installed on the rotor. This preliminary preparation allows for precise control of coil dimensions, winding consistency, and weight distribution to be achieved in a controlled environment, improving both manufacturing precision and overall winding efficiency by reducing on-site adjustment requirements.
3Ease of manufacture
If traditional winding methods are used, then the process is straightforward, but the stacking method of windings is not conducive to the utilization of the space in the slot
Solution Approach 1:
The coil windings are arranged in a three-dimensional configuration within the rotor slots, utilizing axial, radial, and tangential dimensions optimally. Coils are positioned at specific angles and depths within slots, creating a multi-dimensional packing arrangement that maximizes slot fill factor while maintaining electrical performance and mechanical integrity.
Data Source
AI summary
A rotor assembly (100), comprising a rotor (101) and a rotor winding (102). The rotor (101) is provided with a plurality of teeth; tooth slots are provided between adjacent teeth; the rotor (101) can be connected to a rotor shaft to output power; the rotor winding (102) is composed of coils wound on the rotor (101); the rotor winding (102) comprises a portion extending in an axial direction parallel to the rotor assembly (100) and a portion extending in a plane perpendicular to the axial direction; the portion extending in the plane perpendicular to the axial direction comprises a plurality of sections; in the axial direction, the plurality of sections are in one-to-one correspondence to corresponding sides of two or more polygons, respectively. The winding method can solve the problems such as length difference of copper wires between windings due to sequential superposition of the coils in traditional windings, thus achieving the technical effects of improving the balance of the armature and minimizing the difference in resistance of windings.