Rectangular Coil with Arc Corners for Linear Motor Cooling
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Solution Overview
Problem
Existing coil designs for rotating electrical machines and linear motors face challenges in achieving a smooth surface finish and efficient cooling, leading to suboptimal performance and increased size due to protruding wire connections and uneven surface contact.
Innovation Solution
A coil design where the conductor is wound in a circumferential direction with shifting pitches, forming parallel and connecting parts, and pressure molded to create a rectangular shape with arc corners, allowing for smooth straight parts and efficient heat dissipation, while minimizing the size of wire connections and the motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rectangular coil with four straight sides is used, then the structure is simple and easy to manufacture, but the surface finish is rough and cooling efficiency is poor
Solution Approach 1:
The coil is divided into multiple segments including straight parts, corner parts, and arc parts. Each segment serves a specific function: straight parts provide smooth surfaces for cooling, corner parts connect different sections, and arc parts enable smooth transitions. This segmentation allows the coil to achieve both good surface finish and manageable structural complexity.
Solution Approach 2:
The corner parts of the coil are designed with arc shapes instead of sharp angles. These arc parts provide smooth transitions between straight sections, improving the overall surface finish and enabling better contact with cooling surfaces. The curvature radius is specifically controlled to balance smoothness with manufacturing feasibility.
2Reliability
If wire connections protrude from the coil, then electrical connectivity is ensured, but the radial size increases and performance decreases
Solution Approach 1:
The wire connections are nested within the coil structure by extending them along the circumferential direction and embedding them in grooves or channels formed on the coil surface. This nesting approach ensures reliable electrical connectivity while minimizing the radial protrusion, thus reducing the overall radial size and improving motor performance.
3Ease of manufacture
If the coil surface is uneven, then manufacturing is easier, but contact with armature/base is poor and heat dissipation is reduced
Solution Approach 1:
Different parts of the coil are given different surface qualities tailored to their specific functions. The straight parts are designed with smooth surfaces that closely match the armature or base surfaces for optimal heat dissipation. The corner parts and arc parts have slightly different geometries to facilitate manufacturing while maintaining adequate contact. This local differentiation ensures both ease of manufacture and effective thermal management.
4Volume of moving object
If the coil size is reduced, then motor size decreases, but wire connections become more constrained and difficult to implement
Solution Approach 1:
Instead of extending wire connections radially outward (one dimension), the design utilizes the circumferential direction (another dimension) for wire routing. Wires are extended along the circumferential path and embedded in grooves, effectively using the coil's perimeter space. This dimensional shift allows compact radial size while providing adequate space for wire connections, thus reducing motor size without compromising manufacturability.
Data Source
AI summary
This disclosure discloses a coil. An outer shape of the coil as viewed from the first direction has an approximately rectangular shape or an approximately square shape with four corner parts. The coil includes at least one parallel part extended parallelly along the circumferential direction, and at least one connecting part arranged at a portion corresponding to any of the four corner parts, the at least one connecting part being extended along a diagonal direction with respect to the circumferential direction to connect the two parallel parts.