Simultaneous Multi-Phase Winding for Rotary Electrical Machines
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Solution Overview
Problem
The existing methods for winding rotors or stators of rotary electrical machines using continuous wires result in suboptimal notch filling, increased winding time, and magnetic saturation issues due to axial undulations hindering phase insertion and limited notch depth and width.
Innovation Solution
A method where multiple continuous wires are simultaneously inserted into notches, forming a phase, with a distributed undulation pattern that allows for radial insertion and improved wire imbrication, reducing the number of turns and copper usage, and enabling winding on a closed stator with reduced axial undulations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If phases are wound sequentially one after another, then the winding process is simple to implement, but the winding time increases and axial undulations from earlier phases impede insertion of later phases
Solution Approach 1:
The patent merges the winding operations of multiple phases into a single simultaneous operation. Multiple carriages, each carrying notches for different phases, are positioned around the rotor core and wound together in one continuous motion, eliminating the sequential winding process and reducing total winding time.
Solution Approach 2:
The patent introduces dynamic positioning of carriages that can be adjusted radially and axially. The carriages move dynamically during the winding process to accommodate the rotor's rotation and to optimize the insertion path of wires into notches, enabling simultaneous winding of multiple phases without interference from axial undulations.
2Volume of moving object
If notches have limited depth and width to fit within stator inner diameter, then the support can be placed inside the stator, but the notch filling coefficient is reduced and magnetic saturation occurs
Solution Approach 1:
The patent transitions from radial-only wire insertion to a combined radial-axial insertion path. Wires are inserted at an angle that includes both radial and axial components, allowing them to reach deeper into the notches and achieve better filling without increasing the radial dimensions of the notches themselves.
Solution Approach 2:
The patent divides the wire insertion process into multiple segments or stages. Wires are inserted in a stepped manner through the notches, with intermediate positioning points that allow progressive penetration deeper into the notch, achieving better filling coefficient without requiring the entire wire length to be inserted in a single radial motion.
3Ease of manufacture
If multiple turns are wound on a support with open notches and then inserted by thrusting, then the winding can be done in stages, but the support notches have limited dimensions and insertion force requirements increase
Solution Approach 1:
The patent introduces guide elements and positioning mechanisms that act as intermediaries between the wire bundle and the notch. These intermediaries facilitate the insertion process by guiding wires along the correct path, distributing insertion forces, and preventing binding or jamming during the thrusting operation.
Solution Approach 2:
The patent modifies the physical parameters of the insertion process, including the angle of insertion, the speed of insertion, and the sequence in which wires are inserted. By optimizing these parameters, the required insertion force is reduced while still achieving complete filling of the notches.
Data Source
AI summary
A rotary electrical machine comprising a rotor and a stator (1). The stator comprises a tooth (21) delimited by notches (22), and a winding composed of n×M wires (3), wherein n corresponds to a number of phases and is equal to at least 2, and M corresponds to a number of continuous electric wires for each phase (3) and is equal to at least one. The winding is composed of successive turns, each of the successive turns comprising n×M wires wound simultaneously in n of the notches (22) to be inserted in n series of notches. Each of the series of the notches is dedicated to a single phase, and for each of the successive turns, each of the assembly of the M wires (3) constitutes a phase and is inserted in the same series of the notches (22).