Stator Coil Winding With Interturn Insulation for Shape Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Multi-strand conductors tend to change shape when bent, causing damage to the insulating material and creating uneven coil shapes, especially when used in high-power density motors where precise fitment is required.
Innovation Solution
A stator coil is formed by winding a conductor with substantially straight sides and curved ends, and insulating material is provided between the turns during the winding process, rather than pre-coating the conductor, to minimize distortion and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-strand conductors are used to form coils, then current distribution is improved and eddy currents are minimized, but the conductor shape changes when bent causing insulation damage and uneven coil shapes
Solution Approach 1:
The patent applies preliminary action by pre-forming the conductor bundle into the desired coil shape before winding. The conductor bundle is prepared with straight sides and curved ends configured to match the final coil geometry, preventing shape changes during the winding process and eliminating the need for post-winding adjustments or additional insulation layers.
Solution Approach 2:
The patent changes the physical parameters of the conductor bundle by configuring it with specific geometric characteristics - substantially straight sides and opposing curved ends. This parameter change allows the conductor to maintain its shape during winding without the inherent distortion problems of traditional multi-strand conductors, resolving the contradiction between reliability and manufacturing precision.
2Reliability
If insulating material is applied before winding, then electrical insulation is provided, but the insulating material is damaged when the conductor is bent around small radius turns
Solution Approach 1:
The patent reverses the sequence of operations by applying the insulating material after winding rather than before. The conductor bundle is first wound into the coil shape, and then the insulating material is applied to the finished coil. This eliminates the problem of insulation damage during bending since the conductor is shaped first and insulation is added afterward when no further bending occurs.
Solution Approach 2:
The patent inverts the traditional sequence of coil manufacturing by winding the conductor first and then applying insulation, rather than the conventional approach of insulating the conductor before winding. This inversion resolves the contradiction by eliminating the mechanical stress on insulating material during the bending process.
3Reliability
If traditional insulated conductors are wound into coils, then electrical insulation is provided, but the coil becomes bulky requiring additional insulation layers or slot liners
Solution Approach 1:
The patent applies preliminary action by configuring the conductor bundle with pre-formed straight sides and curved ends that match the desired coil geometry. This pre-configuration eliminates shape changes during winding, creating a compact, uniform coil that fits precisely in the stator slot without requiring additional insulation layers or slot liners, thus reducing overall coil volume while maintaining electrical insulation.
Data Source
AI summary
A stator coil includes a conductor wound into a plurality of turns having substantially straight sides and opposing curved ends. The stator coil also includes insulating material provided between the conductor turns and wound into the turns with the conductor. The coil can be formed by winding a conductor in a plurality of turns defined by opposing substantially straight sides an opposing curved ends, and winding an insulating material located below or above the conductor together with the conductor.