Transverse Flux Stator Winding Litz Wire Segmentation
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Solution Overview
Problem
The design of transverse flux machines faces challenges in efficiently producing a stator winding that balances current displacement and internal stresses while maintaining a high copper cross-section, particularly with the use of litz wire configurations.
Innovation Solution
The implementation of a stator winding in the form of a litz wire with 1000 individual copper wires, each 0.2 mm in diameter, wound almost 360 degrees, and insulated with enamel, which is then compressed and connected to minimize current displacement and internal stresses, and further coated with a curable resin for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If litz wire is used for stator winding to maintain high copper cross-section, then current displacement increases and internal stresses increase
Solution Approach 1:
The litz wire is segmented into 1000 individual copper wires, each 0.2mm in diameter, arranged in parallel strands. This segmentation allows each thin wire to handle high-frequency currents independently, reducing the skin effect and proximity effect that cause current displacement, while collectively maintaining a high copper cross-section for current carrying capacity.
Solution Approach 2:
The patent transforms the wire configuration from a single solid conductor to a multi-strand litz wire structure with specific geometric arrangement. By organizing wires in multiple layers and strands with defined spacing and insulation, the solution addresses current displacement in the radial and axial dimensions while preserving the overall copper cross-sectional area.
2Reliability
If litz wire is compressed to reduce internal stresses, then manufacturing complexity increases
Solution Approach 1:
The litz wire is pre-formed with the correct geometric configuration, insulation application, and strand arrangement before installation into the stator winding. This preliminary preparation ensures that the wire structure is optimized to minimize internal stresses under operational conditions, while the standardization of this pre-forming process manages manufacturing complexity through repeatability.
Solution Approach 2:
The patent specifies precise parameters for the litz wire construction including 1000 individual wires of 0.2mm diameter, specific insulation thickness, strand arrangement patterns, and compression dimensions. By controlling these geometric and material parameters, the solution reduces internal stresses through optimized wire structure while maintaining manageable manufacturing complexity through parameter standardization.
3Quantity of substance
If multiple turns are wound almost 360 degrees to maintain high copper cross-section, then winding complexity increases
Solution Approach 1:
The winding is segmented into multiple parallel strands of litz wire, each carrying a portion of the total current. This segmentation allows the winding to achieve high copper cross-section through parallel conductors rather than through complex multi-layer winding patterns, thereby reducing winding complexity while maintaining current carrying capacity.
Solution Approach 2:
Multiple parallel strands of litz wire are combined to form the complete stator winding assembly. By merging several simpler single-strand windings into one multi-strand configuration, the solution achieves the required copper cross-section and current handling capability with reduced individual strand complexity, making the overall winding process more manageable.
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 reduces current displacement and internal stresses, enhancing the performance and stability of the stator winding in transverse flux machines, particularly at 10,000 revolutions per minute, while maintaining a high copper cross-section.
Implementation Method 1
each 0.2 mm in diameter, wound almost 360 degrees, and insulated with enamel
Implementation Method 2
further coated with a curable resin for stability
Data Source
AI summary
The invention relates to a stator winding for a transversal flow machine, the stator winding (98) being embodied as a cord (244) and said cord (244) having a plurality of individual wires (242). Said stator winding (98) is embodied as a coil with several windings (245), characterized in that one or more windings (245) are layered in the axial direction or radial direction.