Stator Coil Assembly Helical Winding for Lamination Factor
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Solution Overview
Problem
Existing methods for manufacturing coil assemblies for electric rotating machines result in reduced lamination factors due to step spaces at loop transitions, and attempts to improve this either degrade performance by using thin wires or increase manufacturing costs and complexity with multiple electrical connections.
Innovation Solution
A method involving the formation of band-like coil wire combinations with interlaced and non-interlaced parts, where coil wires are wound in a helical shape to minimize step spaces at loop transitions, allowing for high lamination factors without performance degradation or increased costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If coil wires are overlapped to form a double-layered structure with successive shifts, then a band-like wire combination is formed, but step spaces appear at loop transitions reducing the lamination factor
Solution Approach 1:
The coil wire combination is divided into multiple individual coil wires (first coil wire, second coil wire, third coil wire, etc.) that are overlapped and interlaced in sequence. Each coil wire forms a distinct layer contributing to the overall band structure, allowing precise control over the arrangement and reducing step spaces at transitions.
Solution Approach 2:
Multiple coil wires are nested within each other in an interlaced configuration where the second coil wire is positioned to overlap with the first coil wire, the third coil wire overlaps with the second, and so on. This nested arrangement creates a compact band-like structure with minimized step spaces at loop transitions, thereby maintaining high lamination factor.
2Manufacturing precision
If coil wires with small cross-sectional area are used to fill step spaces, then lamination factor is improved, but resistance increases degrading machine performance
Solution Approach 1:
The coil wires are formed with a wave shape (curved configuration) rather than straight lines. This curvature allows the wires to naturally conform and fill step spaces at loop transitions through their bent geometry, eliminating the need to reduce wire cross-sectional area. The wave-shaped wires maintain their original cross-section and electrical properties while achieving high lamination factor.
3Manufacturing precision
If multiple cylindrical wire combinations with different diameters are formed concentrically, then loop transition portions are eliminated, but electrical connections are required increasing complexity and cost
Solution Approach 1:
Multiple coil wires are merged into a single continuous band-like wire combination through interlacing and overlapping. The ends of adjacent coil wires are connected to form a unified structure that eliminates the need for separate cylindrical wire combinations and their associated electrical connections. This merging approach maintains structural integrity while reducing complexity.
Solution Approach 2:
The coil wires are pre-formed with wave shapes and predetermined overlap positions before assembly. The interlacing pattern is established in advance during the forming process, ensuring that loop transitions are minimized without requiring subsequent electrical connections between separate components. This preliminary configuration simplifies the overall structure.
Data Source
AI summary
The method of manufacturing a coil assembly for a stator formed with slots includes a coil wire combination forming step of forming a band-like coil wire combination by overlapping a plurality of coil wires while forming them with in-slot portions to be accommodated in the slots and turn portions each connecting each adjacent two of the in-slot portions, and a shaping step of shaping the band-like coil wire combination into a cylindrical shape by helically winding the band-like coil wire combination. The coil wire combination forming step is carried out by performing an interlaced part forming step of forming an interlaced part by overlapping the coil wires with each adjacent two of the coil wires intersecting with each other and a non-interlace part forming step of forming an interlaced part by overlapping the coil wires with each adjacent two of the coil wires not intersecting with each other.