Pretensioned Coil Assembly for Stable Conductor Positioning
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Solution Overview
Problem
Existing coil assemblies in electrical machines and converters experience changes in acoustic and electromagnetic behavior due to temperature fluctuations and aging, leading to issues such as audible hum and loss of tension, which affect their performance over time.
Innovation Solution
A coil assembly design that incorporates a pretensioning element between the electrical conductor and the iron core, maintaining a compressive force to counteract changes in the conductor's position and orientation, ensuring a backlash-free arrangement and minimizing acoustic and electromagnetic disturbances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the electrical conductor is wound tightly around the iron core during manufacturing, then the initial positioning accuracy is improved, but the conductor expands and loosens over time due to temperature fluctuations and aging, leading to play and acoustic hum
Solution Approach 1:
The patent introduces a dynamic adjustment mechanism (adjustable fastening element) that allows the fastening force on the electrical conductor to be modified after assembly. This enables the system to adapt to conductor expansion over time by increasing the fastening force, thereby maintaining consistent positioning accuracy and preventing play formation during the product lifetime
Solution Approach 2:
The patent enables changing the fastening parameter (fastening force) of the electrical conductor on the iron core after assembly. By adjusting this parameter in response to conductor expansion, the system maintains optimal contact pressure and positioning, preventing both initial positioning errors and time-dependent loosening
2Stability of the object's composition
If the electrical conductor is allowed to expand freely with temperature and aging, then the conductor flexibility is maintained, but gaps form between the conductor and iron core causing acoustic hum and electromagnetic instability
Solution Approach 1:
The patent applies a pre-adjusted fastening force through the adjustable fastening element that counteracts the expected conductor expansion over time. This preliminary anti-action prevents gaps from forming between the conductor and iron core, thereby eliminating the conditions that would generate acoustic hum and electromagnetic disturbances
Solution Approach 2:
The patent enables a feedback mechanism where the fastening force can be adjusted based on observed conductor behavior over time. This allows the system to respond to expansion trends and maintain optimal contact, preventing the formation of gaps that would lead to harmful acoustic and electromagnetic effects
3Stability of the object's composition
If a rigid fastening method is used to prevent conductor movement, then positioning stability is improved, but the conductor cannot accommodate thermal expansion leading to internal stresses and potential damage
Solution Approach 1:
The patent employs a dynamic fastening system where the fastening force can be adjusted after assembly. This allows the system to maintain stable positioning while accommodating conductor expansion by increasing the fastening force as needed, preventing both excessive movement and dangerous internal stress buildup
Solution Approach 2:
The patent enables modification of the fastening parameter (force level) to match the conductor's thermal expansion characteristics. By adjusting this parameter over time, the system maintains secure positioning without applying excessive rigid constraints that would cause internal stresses and potential conductor damage
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 pretensioning element maintains a consistent coil assembly performance by compensating for conductor elongation and aging, preventing gaps and maintaining acoustic and electromagnetic stability over the product's lifetime.
Implementation Method 1
the pretensioning element forms a pretensioning force between the iron core and the electrical conductor... the pretensioning element can, for example, consist of a metal spring or a plastic spring
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
Coil assembly (1) for an electric machine (100) or an electric converter, comprising an iron core (2), in particular a laminate pack, around which an electrical conductor (3) is wound to form a winding (4), wherein a receiving body (5) is arranged at least section by section between the iron core (2) and the electrical conductor (3), which has a receiving recess (6) for receiving the electrical conductor (3) at least section by section, wherein at least one pretensioning means (7) is arranged or formed between the electrical conductor (3) and the iron core (2) and forms a pretensioning force (8) between the iron core (2) and the electrical conductor (3) in the final assembly state of the coil assembly (1).