Single-Wire Phase Coil Assembly for Rotary Electric Machines
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Solution Overview
Problem
The existing rotary electric machines face challenges in coupling phase coils due to the high number of wires, which complicates the optimization of magnetic flux flow and slot filling.
Innovation Solution
The solution involves reducing the number of wires per phase coil to one, with each coil comprising straight portions and end-loop portions that link consecutive straight portions in the same layer, facilitating coupling and forming a distributed wave winding with U-turn parts and slope portions for efficient slot filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple wires per phase coil are used to maximize slot filling, then the magnetic flux flow is optimized, but the coupling of phase coils becomes difficult
Solution Approach 1:
The wire assembly is segmented into multiple identical modular units, each comprising a single wire forming a complete phase coil with straight portions and end-loop portions. This segmentation reduces the coupling complexity from managing multiple wires per phase to managing one wire per modular unit, while the modular design enables systematic assembly and optimal slot filling through repeated patterns.
2Quantity of substance
If more wires are used per phase coil, then the slot filling is maximized, but the device complexity increases
Solution Approach 1:
The wire assembly implements local quality by creating distinct regions within the phase coil structure: straight portions for optimal slot filling in specific layers, and end-loop portions for coupling between phases. This localized functional differentiation allows each wire to perform multiple functions efficiently, reducing the total number of wires needed while maintaining complex electromagnetic performance.
3Ease of manufacture
If a single wire per phase coil is used to simplify coupling, then the manufacturing is easier, but the slot filling optimization becomes challenging
Solution Approach 1:
The wire assembly transitions from a two-dimensional planar arrangement to a three-dimensional configuration with straight portions positioned in different layers and end-loop portions connecting these layers. This dimensional transformation allows a single wire to occupy multiple spatial positions, achieving optimal slot filling across multiple layers while maintaining simplified single-wire coupling architecture.
Data Source
Figure 1~3a
Figure 3b~5a
Figure 5b~8
AI summary
The invention relates to a wire assembly for electric rotary machine comprising a plurality of phase coils (P1-P6), each phase coils (P1-P6) being aimed to be inserted in a dedicated set of slots (18) of a stator (10), each phase coil (P1-P6) comprising a first part (61) having an input (I1-I6) and a second part (62) having an output (O1-O6), said first part (61) and second part (62) constituting a distributed wave winding, characterized in that each phase coil (P1-P6) comprises a U-turn part (63) linking the first (61) and the second (62) parts so that each phase coil (P1-P6) is composed of a single wire (23).