Radial Bearing Actuator Coil Flanges for Flexible Core Dimensions
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Solution Overview
Problem
Existing methods for manufacturing magnetic radial actuators require specific tools for laminated core sizes, leading to standardization limitations and time-consuming insulation and mounting operations, restricting the shape and bulk of the laminated core.
Innovation Solution
A radial actuator design featuring separate flanges on either side of the laminated core, allowing independent production and adaptation of coil geometries, with insulating materials to ensure electrical isolation and flexibility in core dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If upstream winding of coils on a tool is used, then coil mounting is achieved, but standardization of laminated core dimensions is required and tool costs increase
Solution Approach 1:
The patent divides the laminated core into modular segments that can be assembled in different configurations. This segmentation allows the same winding tool to accommodate various core dimensions by adjusting the modular segments, eliminating the need for standardized dimensions and expensive multiplication of tools for different sizes.
Solution Approach 2:
The patent designs a universal winding tool capable of accommodating multiple laminated core dimensions through adjustable fixtures and modular support structures. This multi-functional tool can adapt to different core sizes and shapes, eliminating the need for dedicated tools for each dimension and reducing standardization requirements.
2Reliability
If complementary insulation and mounting operations are performed, then electrical insulation is ensured, but manufacturing time increases significantly
Solution Approach 1:
The patent applies electrical insulation treatment to the laminated core before the winding operation. By performing the insulation action in advance, the time-consuming insulation step is decoupled from the critical winding path, allowing parallel processing and significantly reducing total manufacturing time while maintaining insulation reliability.
Solution Approach 2:
The patent integrates the insulation application process with the winding preparation process, combining what were previously separate sequential operations into a unified workflow. This merging eliminates idle time between operations and streamlines the manufacturing process.
3Shape
If coil winding is performed on specific carcasses, then coil geometry is achieved, but standardization of carcass dimensions is required
Solution Approach 1:
The patent employs adjustable and reconfigurable carcass structures that can be dynamically adapted to different coil geometry requirements. The carcass components can be repositioned and reconfigured for various winding patterns and dimensions, eliminating the need for standardized fixed-dimension carcasses while maintaining precise coil geometry control.
4Manufacturing precision
If laminated core shape is constrained by manufacturing operations, then fitting of coil windings is ensured, but design flexibility is reduced
Solution Approach 1:
The patent transitions from constrained two-dimensional laminated core shapes to three-dimensional modular assemblies. By stacking and arranging modular laminated segments in different spatial configurations, the design achieves complex 3D shapes that accommodate various coil winding patterns while maintaining manufacturing precision through the modular interface design.
Data Source
AI summary
A radial actuator for a magnetic radial bearing module. The radial actuator 1 comprises an arrangement of coils 2 that are disposed around a central axis XX′. Each coil is formed by a laminated core 3 and by a winding wire 12 electrically insulated from said laminated core 3. The radial actuator 1 includes two separate opposite flanges 5. The flanges are made of an electrically insulating material. The flanges are disposed on either side of the laminated core 3 of at least one of said coils 2. The winding wire 12 of said coil 2 is wound around the two flanges 5 and coming into contact with said flanges.