Rolled Coil Assembly Layout to Cut Resistance and Raise Torque
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Solution Overview
Problem
The existing coil assemblies in rotating electrical machines face challenges in minimizing size and enhancing torque output due to the use of wiring substrates, which increase electrical resistance and complicate the reduction of power supply line length.
Innovation Solution
A coil assembly design featuring a strip member made from electrical insulating material, rolled into turns, with coils formed on it, allowing for connections that minimize axial size and reduce electrical resistance by eliminating the need for additional conductors, and optimizing coil arrangements to enhance torque output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wiring substrate is used to connect conductive ends, then electrical connection is achieved, but the size of the rotating electrical machine increases and electrical resistance increases
Solution Approach 1:
The patent extracts and eliminates the wiring substrate from the coil assembly structure. Instead of using a separate wiring substrate to connect conductive ends, the invention integrates the connection function directly into the coil structure itself, thereby removing the unnecessary component that increases size and electrical resistance.
Solution Approach 2:
The patent merges the electrical connection function with the coil structure. The conductive ends are directly connected through the coil winding structure itself, combining the functions of electrical connection and coil operation into a single integrated structure, eliminating the need for separate wiring substrates.
2Reliability
If a wiring substrate is used to connect conductive ends, then electrical connection is established, but the length of power supply line increases leading to higher electrical resistance
Solution Approach 1:
The patent removes the wiring substrate that creates excessive power supply line length. By eliminating this intermediate connection component, the power supply path is shortened directly, reducing electrical resistance and energy loss.
Solution Approach 2:
Instead of using a wiring substrate to extend connections, the invention inverts the approach by making the coil structure itself the direct connection path. The conductive ends are connected through the coil winding rather than through an external substrate, thereby minimizing the power supply line length.
3Reliability
If wiring substrate is used for coil connection, then electrical connection is achieved, but the degree of torque output is reduced
Solution Approach 1:
The patent extracts the wiring substrate that is causing increased electrical resistance. By removing this component, the overall electrical resistance of the coil assembly is reduced, allowing for higher current flow and improved torque output capability.
Solution Approach 2:
The invention merges the electrical connection function into the coil structure itself. This integration eliminates the additional electrical resistance introduced by separate wiring substrates, thereby improving the efficiency of electrical-to-mechanical energy conversion and enhancing torque output.
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
This design effectively minimizes the size of the rotating electrical machine while enhancing torque output by reducing electrical resistance and optimizing coil arrangements, leading to improved performance without increasing machine size.
Implementation Method 1
The strip member is rolled in the circumferential direction into a plurality of turns stacked on one another in the radial direction
Implementation Method 2
a rotating electrical machine which comprises a first one of a stator and a rotor which includes an armature according to claim 1, and a second one of the stator and the rotor which includes a magnet arranged to face the coil assembly
Data Source
AI summary
A coil assembly includes a strip member having a width in an axial direction, a length in a circumferential direction, and a thickness in a radial direction of a coil assembly. The strip is rolled in the circumferential direction into a plurality of turns stacked on one another. The coil group includes a plurality of coils made from an electrically conductive material. The coils are arranged in a length direction of the strip. Each of the coils is shaped, to have an open end facing in a first width direction and a closed end facing in a second width direction opposite the first width direction. Two of the coils arranged adjacent each other in the length direction of the strip are connected in a preselected way on a first width end facing away from a second width end portion of the strip in the first width direction.