Tangential Winding Bending for Electric Machine Power Density
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Solution Overview
Problem
Existing electric machines face challenges in achieving high power density while maintaining a compact size, as the effective length of the laminated sheet package limits the output power, especially in space-constrained applications like automotive systems.
Innovation Solution
A method and device for producing windings of a winding carrier, where winding segments are bent tangentially across their length using compressive and frictional forces, eliminating projecting end portions and allowing for a longer laminated sheet package without increasing the overall construction length, thereby enhancing power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the effective length of the laminated sheet package is increased to improve power density, then the power output increases, but the axial length and installation space requirements increase
Solution Approach 1:
The invention changes the bending direction of the winding overhang from the axial direction to the tangential direction. By bending the first region of the winding segment in a tangential direction (first direction) rather than extending it axially, the winding overhang is redirected into the circumferential dimension. This dimensional transformation allows the laminated sheet package to be extended in axial length without proportionally increasing the overall construction length, thereby improving power density while controlling installation space.
2Strength
If the winding overhang is made longer to accommodate winding segments, then the winding structure is more robust, but the laminated sheet package length decreases
Solution Approach 1:
The winding overhang is bent in a tangential direction (first direction) rather than extending axially. This redirects the overhang length into the circumferential dimension, allowing the laminated sheet package to achieve greater axial length for improved robustness while the overall construction length remains controlled by the tangential orientation of the overhang.
Solution Approach 2:
The winding overhang is bent along a curved path defined by the first circle, creating a tangential orientation. This curvature transforms the linear axial extension into a circumferential arc, allowing the overhang to maintain structural robustness while occupying less axial space and enabling a longer laminated sheet package.
3Length of moving object
If forces are applied to bend the first region of the winding segment, then the winding overhang is reduced, but mechanical stress on the winding segment increases
Solution Approach 1:
The invention applies controlled forces (first force and second force) that act in specific directions (axial and tangential components) to bend the first region of the winding segment. By carefully controlling the magnitude and direction of these forces, the winding overhang is reduced to an optimal length while the mechanical stress remains within acceptable limits, achieving a balance between compactness and structural integrity.
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 approach results in a winding carrier with a shorter winding overhang, enabling a longer laminated sheet package and higher power density within the same axial length, reducing mechanical stress and installation height, and improving the efficiency and output of electric machines.
Implementation Method 1
a first force, acting tangentially to the first circle, is subsequently bent in a first direction, tangential to the first circle. For the first region to be bent, forces which, when illustrated as force vectors in a three-dimensional coordinate system
Data Source
AI summary
The disclosure relates to a method for producing a winding of a winding carrier of an electric machine. The method includes providing a laminated core. The laminated core has an axis and a first slot for accommodating a first winding segment for producing the winding. The first slot extends in the direction of the axis. The first slot is arranged on a first circle as viewed in the direction of the axis, through the circle center point of which first circle the axis extends. The method includes: arranging the first winding segment in the first slot, where a first region of the first slot protrudes from the laminated core; and bending the first region by applying a first force acting in the direction of the axis and by applying a first force acting tangentially to the first circle onto the first region in a first direction tangentially to the first circle.