Polyphase Winding Pack Layout for Simpler Slotless Motor Assembly
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Solution Overview
Problem
The existing methods for forming field windings in electric motors are complex and costly, particularly in slotless designs where the lack of teeth results in smooth-running characteristics but increased complexity and cost.
Innovation Solution
A polyphase winding pack is formed with coiled conductors arranged in a two-layer configuration, where the first and second sides of the coils are disposed in sequential layers with a position-maintaining member, such as adhesive tape, to maintain relative positions and facilitate a compact, efficient configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional slotless motor winding methods are used, then smooth-running characteristics are achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The winding pack is divided into multiple discrete coil assemblies, each containing conductors arranged in specific patterns. These segmented coils can be manufactured and positioned independently, simplifying the overall manufacturing process while maintaining the smooth-running characteristics of slotless motors.
Solution Approach 2:
The patent transitions from traditional planar winding arrangements to a three-dimensional stacked configuration where coils are arranged in multiple layers (first layer, second layer, third layer) with specific spatial relationships. This dimensional change allows for more efficient space utilization and simplified manufacturing access.
2Volume of moving object
If coils are arranged in multiple layers with overlapping sides, then space utilization improves, but position maintenance becomes more difficult
Solution Approach 1:
Position-maintaining members are introduced as intermediary elements between the coils and the winding pack structure. These members actively hold the coils in their designated positions, ensuring precise spatial relationships between overlapping coil sides while allowing for dense packing. The position-maintaining members compensate for manufacturing tolerances and maintain alignment during assembly and operation.
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
This approach simplifies the formation and installation of field windings, reducing complexity and cost while maintaining efficient magnetic field alignment and motor performance.
Implementation Method 1
The position-maintaining member may include adhesive tape that extends between the layers
Data Source
AI summary
An electric motor polyphase winding pack includes a plurality of coiled conductors, each of the coiled conductors corresponding to a phase of a plurality of phases. Each of the coiled conductors has a first side and a second side. The coiled conductors are arranged in a sequence in which all of the first sides are disposed sequentially in a first layer, and all of the second sides are arranged in second layer disposed adjacent to the first layer, such that some of the first sides in the first layers and some of the second sides in the second layer correspond to each phase of the plurality of phases.