Wound Rotor Pole Sequence for Robust Wire Crimping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing wound rotor designs for electric machines face issues with mechanical robustness due to poor wire routing and crimping, leading to potential wire slippage, breakage, and mechanical stress under centrifugal forces and vibrations, which complicates the winding process and affects the reliability of connections.
Innovation Solution
A wound rotor design where the winding wire is arranged with poles in a specific order around the main axis, with lugs facilitating the winding process, and the wire rests at non-zero angles before and after the poles, ensuring optimal contact and crimping, thereby enhancing mechanical robustness and reducing stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the winding wire is routed in a conventional sequential order (first to last pole), then the winding process is simple, but the wire positioning in connection hooks is incorrect leading to poor mechanical robustness
Solution Approach 1:
The patent inverts the conventional winding sequence by winding the last pole before the first pole, and the penultimate pole after the last pole. This reversal of the winding order allows the wire to be correctly positioned in the connection hooks while maintaining a simple sequential winding process, thereby resolving the contradiction between manufacturing simplicity and connection reliability.
2Productivity
If the wire is crimped at connection hooks with conventional routing, then the connection is formed quickly, but residual stresses and centrifugal forces cause wire slippage and breakage
Solution Approach 1:
The patent applies preliminary action by pre-positioning the wire at specific non-zero angles around the main axis before crimping occurs. The wire is arranged to rest against the shaft at predetermined angular positions, ensuring optimal positioning before the crimping operation. This preliminary arrangement prevents wire slippage and breakage under centrifugal forces while maintaining quick connection formation.
3Reliability
If the wire rests at non-zero angles around the main axis, then mechanical robustness is improved, but the winding process complexity increases
Solution Approach 1:
The patent changes the angular position parameter of the wire around the main axis, specifying non-zero angles for wire placement upstream of the first pole and downstream of the last wound pole. By defining specific angular parameters for wire positioning, the patent achieves improved mechanical robustness while keeping the winding process manageable through parameter specification rather than complex procedural changes.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a wound rotor (20), in particular a wound rotor (20) for an electric machine (30), the wound rotor (20) comprising a shaft (21) having a main axis (A), the shaft (21) comprising a manifold (22), the wound rotor (20) comprising a winding wire (25) and n poles (1, 2, 3,... n-2, n-1, n) wound and ordered with an ascending order number obtained by rotation about the main axis (A), in particular n wound poles (1, 2, 3, …, n-2, n-1, n) distributed radially about the main axis (A), the n poles being wound with the wire (25) in series in turn according to their ascending order numbers, the last pole (n), however, not being wound last.