Preformed Coil Interlacing Tool Radial Arrangement
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Solution Overview
Problem
Existing methods for producing electrical machine windings with preformed coils struggle to achieve optimal space utilization, especially when dealing with winding schemes that have an odd number of conductor strands, leading to irregular coils and poor slot fill factors.
Innovation Solution
A method involving an interlacing tool with concentric cylindrical parts that reshape and interlock U-shaped preformed coils, allowing for even distribution and arrangement of conductor legs in a ring shape, enabling efficient insertion into machine components without leaving empty spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional interlacing methods are used for preformed coils, then the process is simple, but space utilization on the end face deteriorates and slot fill factor decreases
Solution Approach 1:
The patent transitions from conventional planar interlacing to three-dimensional radial arrangement. Conductor legs are arranged radially around a central axis, with conductor arcs extending in the axial direction. This dimensional change allows compact packaging while maintaining electrical connectivity, resolving the contradiction between manufacturing simplicity and space utilization.
Solution Approach 2:
The patent employs curved conductor arcs that radially extend from the end face toward the central axis. This curved geometry allows the conductor legs to be packed more efficiently in the radial direction while maintaining the necessary electrical connections, improving end face area utilization compared to straight conductor arrangements.
2Adaptability or versatility
If preformed coils are arranged to achieve odd number of conductor strands per slot, then winding scheme flexibility improves, but slot fill factor deteriorates due to empty spaces
Solution Approach 1:
The patent arranges conductor legs radially around a central axis rather than in conventional planar slots. This radial three-dimensional arrangement allows odd numbers of conductor strands to be packed efficiently without creating empty spaces, as the conductors naturally distribute themselves along the radial and axial dimensions. This resolves the contradiction between winding flexibility and conductor density.
3Reliability
If conductor arcs are intertwined to comply with winding scheme, then electrical connectivity improves, but manufacturing complexity increases
Solution Approach 1:
The patent employs a universal interlacing tool design that can accommodate different winding schemes and conductor strand configurations through a single radial arrangement mechanism. The tool uses standardized receiving openings and radial positioning features that work for various winding patterns, reducing manufacturing complexity while maintaining reliable electrical connectivity through consistent radial interlacing.
Data Source
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AI summary
The invention relates to a method for producing a winding for a machine component comprising the following steps: arrangement multiple essentially U-shaped pre-formed coils (5) in an entanglement tool (40); shaping the plurality of pre-formed coils (5) by relative movement of tool parts (41, 42) of the entanglement tool (40), wherein the spacing of conductor legs (51) parallel to each other is increased and wherein the shaping is carried out such that conductor legs (51) of different pre-formed coils (5) are arranged in a radial direction to each other; and displacing at least one part of the radial arrangement of conductor legs (51) in a radial direction so that all radial arrangements of conductor legs (51) are arranged in a ring shape.