Single Flyer Winding for Compact Four-Pole Motor
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Solution Overview
Problem
Existing motor designs face challenges in reducing size and weight while maintaining efficient coil winding operations, as increasing the number of poles leads to smaller slots, making coil winding difficult and potentially damaging equalizers due to high current flow, and require complex winding devices like double flyers.
Innovation Solution
A four-pole, six-slot, twelve-segment motor design with a single flyer for continuous coil winding, where the coil is wound around each tooth and connected to segments with a specific sequence to reduce current through equalizers and simplify the winding process, improving the space factor and reducing device complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the number of poles is increased to reduce motor size and weight, then the armature core size and weight are reduced, but the number of slots increases making coil winding difficult
Solution Approach 1:
The armature core is divided into a specific number of slots (six slots for four poles) to create optimal winding conditions. This segmentation allows the coil to be wound efficiently while maintaining the reduced pole count configuration, thus preserving the weight reduction benefit while enabling manufacturable coil winding operations.
2Power
If traditional coil winding methods are used with increased poles, then more magnetic flux can be utilized, but equalizers may be damaged due to high current flow
Solution Approach 1:
The patent modifies the electrical connection parameters by establishing specific connections between coils and commutator segments. This parameter change optimizes the current distribution pathway, reducing the current flow through equalizers to prevent damage while maintaining effective magnetic flux utilization for motor power output.
3Ease of manufacture
If complex winding devices like double flyers are used to handle increased slots, then coil winding becomes feasible, but device complexity increases
Solution Approach 1:
Instead of using a complex double flyer device, the patent employs a simpler single flyer that performs partial winding actions. The coil is wound around specific teeth and connected to specific segments in a predetermined sequence, achieving the necessary winding coverage without requiring the full complexity of a double flyer system.
4Volume of moving object
If the armature core is downsized to reduce motor size, then overall motor dimensions are reduced, but slot size decreases making coil winding more difficult
Solution Approach 1:
The patent applies local quality optimization by designing specific slot dimensions and coil winding patterns tailored to the downsized armature core. The six slots are configured with dimensions and positions that facilitate coil winding despite the reduced overall size, creating locally optimized winding conditions within the compact motor structure.
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 motor is reduced in size, prevents high current flow through equalizers, simplifies the winding device, and enhances the space factor of the coil, facilitating easier winding operations compared to traditional designs.
Implementation Method 1
a predetermined magnetic field is formed in the armature core, and magnetic attractive force or repulsive force is generated between the magnetic field and the permanent magnet
Implementation Method 2
magnetic attractive force or repulsive force is generated between the magnetic field and the permanent magnet. Hence, the armature rotates
Implementation Method 3
A brush comes into slide contact with each segment. The brush is electrically connected to an external power supply. By applying the power of the external power supply to each segment via the brush, a current is supplied to each coil
Data Source
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AI summary
According to the present invention, a coil (7) is continuously wound in a single pass around each of a series of teeth (50), and connected to each segment (14).