Compact Insertion of Multiphase Pseudo Helical Wave Windings
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Solution Overview
Problem
Current methods for inserting thick conductor wave windings into electrical machines are time-consuming, expensive, and prone to poor connections and reduced heat dissipation due to manual procedures and existing automated processes that do not achieve optimal compactness and efficiency.
Innovation Solution
A method and apparatus for compact insertion of thick conductor pseudo helical wave windings into a ferromagnetic core using a pre-formed wire band with specific geometry, allowing for gradual and controlled insertion with variable force, and a programmable, computer-controlled apparatus to ensure accurate and efficient placement without damaging conductor insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual winding procedures are used for thick conductor wave windings, then flexibility and adaptability are maintained, but the process becomes time-consuming and expensive
Solution Approach 1:
The winding process is segmented into distinct operational phases: feeding the conductor, positioning it in the slot, inserting it, and compacting it. Each phase is handled by specialized modules that can be independently controlled and optimized, enabling automated high-speed operation while maintaining the flexibility of manual procedures.
Solution Approach 2:
The apparatus employs dynamic force control during insertion, where the insertion force is adjusted based on real-time feedback from force sensors. This allows the system to adapt to variations in conductor properties and slot conditions, maintaining optimal insertion conditions throughout the automated process.
2Productivity
If existing automated bobbin processes are used, then productivity increases, but manufacturing precision deteriorates due to poor connections and insulation damage
Solution Approach 1:
The conductor is pre-positioned and aligned in the slot before insertion force is applied. The feeding module delivers the conductor to a precise starting position, and the positioning module ensures proper alignment with the slot, preventing misalignment and insulation damage during the high-speed automated insertion process.
Solution Approach 2:
Force sensors mounted on the insertion module provide real-time feedback on the insertion force applied to the conductor. This feedback is used by the control system to adjust the insertion parameters, ensuring consistent connection quality and preventing insulation damage while maintaining high productivity.
3Ease of operation
If segments are inserted with loose fit to ease insertion, then ease of operation improves, but heat dissipation ability deteriorates severely
Solution Approach 1:
The insertion process occurs in periodic cycles: a controlled insertion force is applied to place the conductor in the slot, followed by a compaction phase where the conductor is pressed firmly against the slot walls. This periodic application of force ensures both easy insertion and optimal thermal contact, eliminating the need for loose fit insertion.
Solution Approach 2:
The insertion force parameter is dynamically changed during the process. Initially, a moderate force is applied to insert the conductor without damage, then the force is increased during the compaction phase to ensure tight thermal contact with the slot walls, optimizing heat dissipation while maintaining ease of operation.
4Manufacturing precision
If variable insertion force is applied to achieve optimal compactness, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
Force sensors act as intermediaries between the insertion mechanism and the control system. These sensors measure the actual insertion force and provide feedback to the controller, which adjusts the force parameters to achieve optimal winding compactness. This intermediary measurement system enables precise control without requiring overly complex device architecture.
Data Source
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AI summary
A method and an apparatus for compact insertion of thick wire multiphase pseudo helical wave winding into a ferromagnetic core of an electrical machine, achieving high fill factor of the core slots, resulting in better heat transfer between the winding and the core, low mass and volume, and overall higher efficiency of electrical machine. An apparatus being fully programmable and physically adaptable to wide range of electric machine dimensions, where process is automated, simple, accurate, reliable and quick, while being suitable for mass production.