Powder-Pressed Coil-Tooth Module for Higher Motor Fill Factor
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Solution Overview
Problem
Wound coils in electrical machines do not optimally fill available installation space, leading to lower power or torque density, and the contact between coils and teeth is not ideal, affecting thermal and magnetic properties.
Innovation Solution
A method involving a prefabricated coil inserted into a press mold, filled with metallic powder, and compacted to form a tooth, creating a large contact surface and eliminating cavities for improved thermal and magnetic coupling, without the need for a potting compound.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wound coils are used in electrical machines, then the coils can be easily manufactured and installed, but they do not optimally fill the available installation space resulting in lower power or torque density
Solution Approach 1:
The invention changes the geometric parameters of the coil from a standard wound cylindrical shape to a cast or formed shape with variable cross-section. The inner contour of the coil is specifically designed to match the tooth geometry, allowing optimal filling of the installation space while maintaining ease of manufacture through casting or forming processes.
Solution Approach 2:
The invention uses composite construction by filling the inner contour of the coil with metallic powder (SMC) that is then compacted to form an integrated tooth structure. This composite approach combines the coil winding with the tooth structure, eliminating gaps and optimizing space utilization to improve power density.
2Ease of operation
If undersized dimensions are used for mounting coils on teeth, then the coils can be mounted, but the contact between coil and tooth is not ideal affecting thermal and magnetic properties
Solution Approach 1:
The invention merges the coil mounting function with the tooth structure by filling the inner contour of the coil with metallic powder that forms an integrated tooth. This eliminates the separate mounting operation and creates ideal thermal and magnetic contact between the coil and tooth structures, as they become mechanically and thermally integrated.
Solution Approach 2:
The invention implements nesting by placing the coil around the metallic powder core, where the powder is compacted to form the tooth structure. The coil is nested around the tooth, creating a tight fit with maximum contact surface area, which optimizes both thermal conduction and magnetic coupling.
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 method enhances thermal contact and magnetic permeability, improving heat dissipation and filling the installation space effectively, while eliminating the need for a potting compound.
Implementation Method 1
the metallic powder is compacted by means of the press mold, for example using a plunger, and formed into a tooth
Implementation Method 2
Due to the pressure of several hundred megapascals present during pressing, form fit arises between the particles
Implementation Method 3
improved thermal contact between the coil and the tooth, and improved magnetic properties of the coil-tooth module. This improves the heat dissipation of the coil
Implementation Method 4
it may additionally be provided to excite the metallic powder, during filling or prior to pressing, to flow, for example by means of vibration or shaking of the press mold
Data Source
AI summary
The invention relates to a coil-tooth module and to a method for the production thereof. A prefabricated coil is filled with a metallic powder, and this powder is subsequently pressed to form a tooth, so that a coil-tooth module is created, in which the tooth directly abuts the coil.