Rotating Electrical Machine Coil With Separable Ends
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional stator coils in rotating electrical machines require complex coil ends with specific shapes for each product number, making manufacturing and storage challenging, and the process of connecting coil ends to linear parts is cumbersome, particularly due to the need for precise shaping and assembly.
Innovation Solution
The design introduces a separable coil end that is electrically connectable to the linear part using adapters, allowing for flexible and detachable connections, and utilizes a flexible cable for the coil end to simplify the manufacturing process and eliminate the need for complex shaping, enabling easier assembly and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a unitary coil structure with a specifically shaped coil end is used, then the electrical performance is improved, but the manufacturing complexity and storage difficulty increase
Solution Approach 1:
The coil is divided into two separate parts: a linear part and a coil end part. The linear part maintains the traditional wound structure for electrical performance, while the coil end part is separately formed and connected via an adapter. This segmentation eliminates the need for complex integrated shaping while preserving electrical functionality.
Solution Approach 2:
An adapter is introduced as an intermediary component to connect the linear part and the coil end part. The adapter simplifies the connection process and allows each part to be manufactured independently with simpler tooling, while still achieving the required electrical and mechanical connection.
2Reliability
If a specifically shaped coil end is used for each product number, then the electrical performance is optimized, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
By segmenting the coil into standardizable parts (linear part and coil end part), each component can be manufactured using standardized processes. The linear part can be wound using conventional automated equipment, and the coil end part can be formed separately, both with simpler tooling that reduces manufacturing time and increases productivity.
Solution Approach 2:
The adapter serves as a universal connection component that can be used across different product numbers. This standardization allows the same adapter design to connect various linear parts and coil end parts, reducing the need for custom tooling for each product variant and thereby improving manufacturing efficiency.
3Reliability
If a specifically shaped coil end is used, then the electrical performance is improved, but the assembly process becomes more difficult and time-consuming
Solution Approach 1:
The adapter acts as an intermediary that provides a standardized, easy-to-connect interface between the linear part and the coil end part. This intermediary component simplifies the assembly process by providing alignment features and connection mechanisms that are easier to handle than traditional integrated coil structures, thereby improving ease of operation.
Solution Approach 2:
The adapter and coil end part are designed to self-align and self-secure during assembly. The coil end part can be easily attached to the adapter with minimal manual intervention, and the connection inherently provides its own alignment and securing functions, reducing the complexity of the assembly process.
Data Source
AI summary
According to one embodiment, there is provided a rotating electrical machine coil with a conductor and an insulation layer that is provided around the conductor to cover the conductor, the rotating electrical machine coil including a linear part of the coil and a coil end that is separable from and electrically connectable to the linear part of the coil.