Slot-Less Motor Coil Layout for Interference-Free Assembly
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Solution Overview
Problem
The existing slot-less motor designs face physical interference issues when attempting to assemble the last coil radially inside already assembled coils, preventing the completion of the coil assembly.
Innovation Solution
The slot-less motor incorporates a stator with a coil assembly comprising air core coils, where the effective coil portions of each coil are arranged adjacent to each other in a circumferential direction, with the first coils having their ends radially inside the second coils, and a back-yoke disposed radially outside the second coils, allowing for the assembly of the last coil without interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the last coil is attached from radially inside the already assembled coils, then the assembly process can be completed, but physical interference occurs between the coils making assembly impossible
Solution Approach 1:
The coil assembly is divided into two distinct types: first coils with smaller radial dimensions and second coils with larger radial dimensions. This segmentation allows the first coils to be positioned radially inside the second coils without physical interference, enabling the assembly process to be completed by attaching the last coil from the radial inside.
Solution Approach 2:
Different radial dimensions are assigned to different coil types based on their specific positions and functions in the assembly. The first coils are designed with smaller radial dimensions suitable for inner positioning, while the second coils have larger radial dimensions for outer positioning. This local differentiation of geometric properties eliminates interference and enables successful assembly.
2Quantity of substance
If coils are arranged to achieve high space factor, then motor performance is enhanced, but physical interference prevents proper assembly
Solution Approach 1:
The coil assembly is segmented into first coils and second coils with different radial dimensions. The first coils are positioned radially inside the second coils, creating a compact nested arrangement that maximizes space utilization while avoiding physical interference between coils of the same type.
Solution Approach 2:
The first coils are nested radially inside the second coils, creating a compact hierarchical structure. This nesting arrangement optimizes the space factor by efficiently packing coils in concentric layers, while the clear radial separation between different coil types prevents physical interference during assembly and operation.
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
This configuration enables the assembly of the last coil from the radial inside without physical interference, facilitating a high space factor and uniform conductor arrangement within the coil sections, thereby enhancing the motor's assembly efficiency and performance.
Implementation Method 1
a rotor (300) including permanent magnets (320) and rotating around a center axis (C), and a stator (200) including a coil assembly (230) made of a combination of a plurality of coils (210, 220)
Data Source
AI summary
A slot-less motor includes a rotor and a stator which is equipped with a coil assembly made of a combination of a plurality of coils. Each of the coils is designed as an air core coil which includes a pair of effective coil portions and a pair of coil ends. The coils assembly has the effective coil portions each of which is disposed in air cores of the respective adjacent coils. The coils include first coils each of which is not located between a center line and each of outer outlines of a respective adjacent one of the first coils.