Rotor Winding Guide Geometry for Stable Wire Turn Arrangement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current winding guides produced by injection molding for electric machine rotors have draft angles that lead to inconsistent winding spaces, causing electric wire turns to be randomly superposed and reducing the performance of electric machines due to mechanical stresses at high rotation speeds.
Innovation Solution
Designing winding guides with specific angled ribs and stops that minimize draft angles only where necessary for mold stripping, ensuring a constant winding space width by using a combination of inclined main portions and small, flat-vertex ribs, allowing for precise and consistent electric wire arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a draft angle is applied to the inner face of the head for mold stripping, then ease of manufacture is improved, but manufacturing precision deteriorates due to random superposition of electric wire turns
Solution Approach 1:
The inner face of the head is segmented into two distinct zones: a first portion with a draft angle for mold stripping and a second portion with a substantially perpendicular face for precise wire arrangement. This segmentation allows each zone to fulfill its specific function without compromising the other.
Solution Approach 2:
Different portions of the inner face are given different geometric properties: the first portion has an inclined draft angle optimized for mold stripping, while the second portion has a perpendicular face optimized for wire alignment. Each local area is optimized for its specific purpose.
2Manufacturing precision
If the radial dimension of the winding space is kept constant for consistent wire arrangement, then manufacturing precision is improved, but ease of manufacture deteriorates due to difficulty in mold stripping
Solution Approach 1:
The head structure is divided into two functional portions: a first portion with draft angle that facilitates mold stripping, and a second portion with perpendicular face that maintains constant radial dimension for precise wire arrangement.
Solution Approach 2:
The solution transitions from a single inclined plane to a two-stage geometric structure where the wire path first encounters the draft angle portion and then the perpendicular portion, effectively adding a dimensional step to the surface profile.
Data Source
AI summary
A winding guide for an electric machine rotor includes a base that is substantially circular about a longitudinal axis, teeth which rise radially from the base, and heads which extend at the free ends of the teeth and which project from the teeth, in cantilevered fashion. At least one of the heads has an inner face turned towards the base including a flat main portion which is inclined by a first angle strictly greater than 0 degrees with respect to the longitudinal axis, and ribs which protrude from the main portion and the vertices of which are flat and inclined with respect to the longitudinal axis by a second angle comprised between zero degrees and the first angle.