Rectangular Electric Conductor with Localized Insulation for Coil Bending
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Solution Overview
Problem
The existing rotating electric machines face an issue where the electric conductor wires separate during bending, leading to an increased size of the stator coil and the entire machine due to different radii of curvature, which affects the machine's efficiency and size.
Innovation Solution
The electric conductor features a pair of wires with a substantially rectangular cross-section and an insulating coat with thick portions at the boundary between the wires, which enhances the insulating coat's strength and prevents separation during bending, allowing the wires to maintain alignment and reduce eddy current loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the electric conductor is bent to form a coil, then the coil can be received in the stator core slots, but the electric conductor wires separate due to different radii of curvature, increasing the coil size
Solution Approach 1:
The insulating coat is pre-formed with thick portions at the boundaries between electric conductor wires before bending. This preliminary structural preparation ensures that when the conductor is bent into a coil, the thick insulating portions prevent wire separation caused by different radii of curvature, maintaining wire alignment throughout the bending process
Solution Approach 2:
The insulating coat is designed with non-uniform thickness, featuring thick portions specifically at the boundaries between electric conductor wires and thinner portions elsewhere. This local quality enhancement provides targeted reinforcement exactly where wires are most prone to separation during bending, while maintaining overall compactness
2Stability of the object's composition
If the insulating coat is made thicker to prevent wire separation, then wire alignment is maintained, but the overall size of the electric conductor increases
Solution Approach 1:
The insulating coat thickness is optimized locally rather than uniformly throughout. Thick portions are concentrated only at the critical boundaries between electric conductor wires where separation occurs during bending, while other areas maintain minimal necessary thickness. This localized reinforcement prevents wire separation without unnecessarily increasing the overall conductor volume
Solution Approach 2:
The insulating coat provides more than minimum required insulation only where absolutely necessary (at wire boundaries during bending), rather than uniformly throughout. This partial excessive action ensures wire alignment is maintained during the critical bending operation while minimizing overall volume increase
Data Source
AI summary
An electric conductor is provided for forming a coil upon being bent. The electric conductor includes a pair of electric conductor wires and an insulating coat. The electric conductor wires each have a substantially rectangular cross section and are arranged in alignment with each other in an alignment direction. The alignment direction is perpendicular to corresponding sides of the substantially rectangular cross sections of the electric conductor wires; the corresponding sides have the same length. The insulating coat is formed on outer peripheral surfaces of the electric conductor wires. The insulating coat has a thick portion formed at a boundary between the electric conductor wires. The thick portion is thicker than and protrudes outward from other portions of the insulating coat which adjoin the thick portion in a circumferential direction of the electric conductor.