Rectangular Segment Coil Layout Without Axial Extension
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Solution Overview
Problem
Existing rotating electric machines face issues of increased size, weight, and processing costs due to the use of rectangular wire coils, which require complex bending and alignment processes, leading to insulation and welding failures.
Innovation Solution
A rotating electric machine design utilizing rectangular wire segment coils with a first region portion along the axial direction and a second region portion along the circumferential direction, connected by conductive portions with electron beam or laser welding, eliminating the need for axial extensions and complex bending, and allowing for simplified coil assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a rectangular wire coil is used to increase conductor cross-sectional area, then copper loss is reduced, but the axial length increases due to the third straight portion, increasing motor size and weight
Solution Approach 1:
The patent applies dimensional change by transitioning from a conventional configuration with three straight portions (requiring axial extension) to a U-shaped coil configuration where the connection portion is formed in the circumferential direction. This allows the conductor to achieve the necessary cross-sectional area without increasing axial length, as the connection is made in the radial-circumferential plane rather than extending axially.
Solution Approach 2:
The patent segments the conductor into multiple sections: insertion portions that fit into stator slots, a U-shaped connection portion, and straight portions for welding. This segmentation allows each part to be optimized independently - the insertion portions maintain compact axial length while the U-shaped connection provides the necessary electrical connection without axial extension.
2Loss of energy
If a rectangular wire coil is used to increase conductor cross-sectional area, then copper loss is reduced, but the number of bending steps increases to two per coil piece, increasing processing cost
Solution Approach 1:
The patent applies preliminary action by pre-forming the U-shaped connection portion during coil manufacturing before assembly. This allows the complex U-shaped geometry to be created once during coil production rather than requiring multiple bending operations during final assembly, reducing both the number of processing steps and the risk of insulation damage during assembly operations.
3Manufacturing precision
If a swaging tool is used to fix the third straight portion, then positional deviation is prevented, but the number of components and work steps increases, increasing cost
Solution Approach 1:
The patent extracts and eliminates the need for swaging tools by redesigning the coil connection geometry. The U-shaped connection portion with its specific configuration allows for self-alignment and secure positioning through the winding structure itself, removing the requirement for additional positioning components and tools.
4Device complexity
If the third straight portion is not fixed with a swaging tool, then component count is reduced, but welding failure occurs due to positional deviation
Solution Approach 1:
The patent applies preliminary action by pre-forming the U-shaped connection portion during coil manufacturing before assembly. This allows the complex U-shaped geometry to be created once during coil production rather than requiring multiple bending operations during final assembly, reducing both the number of processing steps and the risk of insulation damage during assembly operations.
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
The design achieves high efficiency and reliability without increasing size or cost, reducing the number of components and processing steps, and preventing insulation and welding failures.
Implementation Method 1
connected by conductive portions with electron beam or laser welding
Implementation Method 2
connected by conductive portions with electron beam or laser welding
Data Source
AI summary
A rotating electric machine having high efficiency and high reliability without causing an increase in size and cost is realized. Each of the rectangular wire segment coils has a first region portion and a second region portion connected to the first region portion and formed in the circumferential direction. Adjacent pairs of wire coils include a conductive portion to which the first region portion of one of the rectangular wire segment coils and the second region portion of the other of the rectangular wire segment coils are connected. Each of the plurality of layers includes a first layer in which the first region portion appears at an axial end portion and a second layer in which the second region portion appears at an axial end portion when the coil end is viewed in an axial direction of the rotating electric machine.