Toothless Armature Coil Assembly Using Segmented Partial Windings
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Solution Overview
Problem
Existing rotating electric machines with a toothless armature structure face challenges in efficiently assembling the armature coil, leading to increased manufacturing device size and complexity.
Innovation Solution
The implementation of a support member system with partial windings, intermediate conductor portions, and bridging portions that are multiply wound and interconnected, allowing for alignment and easy mounting of the armature coil phases, even without teeth, using a common fixing member for the mounting members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the armature coil is directly wound on the armature core in a toothless structure, then the manufacturing device size increases, but the assembly simplicity is improved
Solution Approach 1:
The armature coil is divided into multiple partial windings (first partial windings and second partial windings) that are assembled separately and then combined. This segmentation allows for simpler, smaller manufacturing devices to assemble each portion independently, rather than requiring a large device to wind the entire coil at once.
Solution Approach 2:
The partial windings are prepared and positioned in advance on the armature core before final assembly. The first partial windings are placed in first slots and the second partial windings in second slots, with their ends extending to overlap. This preliminary positioning simplifies the final assembly process and reduces the complexity of the manufacturing device needed.
2Ease of manufacture
If the armature coil is directly wound on the armature core, then the assembly process is simplified, but the device complexity increases
Solution Approach 1:
The manufacturing process is segmented into separate steps for assembling first partial windings and second partial windings. Each segment uses simpler, less complex equipment, avoiding the need for a single complex device that would be required to wind and assemble the entire coil in one operation.
Solution Approach 2:
The partial windings are pre-assembled and positioned in their respective slots before final connection. This preliminary action allows each manufacturing step to use simpler, more straightforward equipment rather than requiring a complex integrated system to perform all operations simultaneously.
3Manufacturing precision
If partial windings are assembled with intermediate conductor portions and bridging portions, then the assembly precision is improved, but the structure complexity increases
Solution Approach 1:
Each partial winding is a discrete, standardized component with defined intermediate conductor portions and bridging portions. This segmentation into identical or similar modular units simplifies manufacturing and assembly precision requirements, as each module can be produced and assembled using the same standardized process.
Solution Approach 2:
The intermediate conductor portions and bridging portions are formed as integral parts of each partial winding during the winding process. This preliminary formation ensures precise geometry and electrical connections are built into each module before assembly, reducing the need for complex post-assembly adjustments.
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 simplifies the assembly of the armature coil, reduces the size of manufacturing devices, and maintains insulation properties, enabling efficient construction and operation of the rotating electric machine.
Implementation Method 1
each of the partial windings has a pair of intermediate conductor portions and a pair of bridging portions, the pair of intermediate conductor portions each extending in an axial direction and being located at a predetermined interval in the circumferential direction, the pair of bridging portions being located respectively on opposite axial sides of the pair of intermediate conductor portions to connect the pair of intermediate conductor portions
Data Source
AI summary
A rotating electric machine includes an armature coil having a plurality of phase windings for respective phases. Each of the phase windings is constituted of a plurality of partial windings each having a pair of intermediate conductor portions and a pair of bridging portions connecting the pair of intermediate conductor portions. All the intermediate conductor portions of the partial windings are arranged in a predetermined sequence in a circumferential direction. At each of coil ends of the armature coil, the bridging portions of the partial windings of different phases intersect one another. Each of the partial windings has a mounting member provided integrally therewith for mounting it to a support member. For each circumferentially-adjacent pair of the partial windings whose bridging portions intersect one another, the mounting members provided respectively integrally with the pair of the partial windings are together fixed to the support member by a common fixing member.