Rotary Electric Machine Armature Coil Segmentation
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Solution Overview
Problem
The complex arrangement of coil ends in rotary electric machines makes the winding process difficult due to interference between adjacent armature coils, requiring adjustments and shaping to avoid obstacles, which complicates the manufacturing process and affects operating characteristics.
Innovation Solution
The rotary electric machine design features armature coils with base, upper layer, and lower layer coils arranged in an overlap winding configuration, where the coil ends of the base coils span N+1 magnetic pole teeth and those of the upper and lower layer coils span N, with specific virtual coil pairs created to avoid interference, allowing for easier winding and improved manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If armature coils are wound in a two-layer overlap winding configuration, then good operating characteristics are achieved, but the coil ends form obstacles that interfere with adjacent coils making winding difficult
Solution Approach 1:
The armature coils are segmented into three distinct types: base coils with one coil side in the upper opening and one in the lower opening, upper layer coils with both coil sides in the upper opening, and lower layer coils with both coil sides in the lower opening. This segmentation allows each type to be wound independently without interference from adjacent coils, resolving the technical contradiction by maintaining the overlap winding configuration for good operating characteristics while eliminating the interference problem that complicates the winding process.
2Ease of manufacture
If coil lengths are adjusted and coil ends are shaped to avoid interference, then winding difficulty is reduced, but the manufacturing process becomes more complex
Solution Approach 1:
The invention extracts and eliminates the problematic coil ends that cause interference between adjacent coils. By configuring base coils to have one coil side in the upper opening and one in the lower opening, and by positioning upper and lower layer coils appropriately, the design removes the interfering elements entirely. This approach maintains ease of manufacture without requiring additional coil length adjustments or shaping operations that would increase manufacturing process complexity.
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 facilitates easier manufacturing and improves operating characteristics by reducing the complexity of coil winding and avoiding interference, while maintaining good torque and vibration characteristics.
Implementation Method 1
an armature coil group having a plurality of armature coils each including a pair of coil sides arranged in the slots, which are different from one another, and coil ends connecting the pair of coil sides... and a rotor having a plurality of magnetic poles aligned in the circumference direction, the rotor being rotated with respect to the armature core and the armature coil group
Data Source
AI summary
In a rotary electric machine, an armature core includes a plurality of magnetic pole teeth and slots are formed between the magnetic pole teeth. An armature coil group includes a plurality of armature coils each including a pair of coil sides arranged in the slots, which are different from one another, and coil ends connecting the pair of coil sides. The armature coil group includes, as the armature coils, a plurality of base coils, of which one coil side is arranged in an upper opening of the slot and the other coil side is arranged in a lower opening of the slot, upper layer coils, of which both one coil side and the other coil side are arranged in an upper opening of the slot, and lower layer coils, of which both one coil side and the other coil side are arranged in the lower opening of the slot.