Toothless Armature Winding Support for Resin-Sealed Rotary Machines
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Solution Overview
Problem
Rotary electric machines with toothless armature structures face challenges in maintaining the position and heat dissipation of armature windings due to gaps and air gaps, leading to reduced performance and potential resin leakage.
Innovation Solution
A cylindrical covering member made of non-magnetic material is used to hold the armature winding in place, with resin filling between the winding holding member and the covering member to prevent leakage and enhance heat dissipation, while a position restriction member ensures proper alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a toothless armature structure is used, then the rotary electric machine achieves a simpler structure and higher speed performance, but the armature winding positional stability deteriorates due to gaps and air gaps
Solution Approach 1:
A resin layer is introduced as an intermediary substance between the armature winding and the winding holding member. This resin layer fills the gaps and air gaps that would otherwise cause positional instability, while allowing the toothless structure to maintain its high-speed performance advantages. The resin acts as a mediating element that provides positional stability without requiring a complex toothed structure.
2Stability of the object's composition
If resin is used to fill gaps for positional stability, then armature winding position is maintained, but resin leakage occurs reducing reliability
Solution Approach 1:
The winding holding member is designed with a preliminary structure that includes recesses and positioning features that constrain the resin layer before operation begins. This preliminary structural arrangement prevents resin leakage during operation by establishing containment boundaries in advance, ensuring both positional stability and reliability.
Solution Approach 2:
The resin layer is configured as a thin film that conformally coats the armature winding and fills gaps. This thin film approach provides effective gap filling for positional stability while minimizing the total volume of resin used, thereby reducing the risk and potential for leakage compared to bulk resin applications.
3Stability of the object's composition
If gaps are reduced for better winding support, then positional stability improves, but heat dissipation performance deteriorates
Solution Approach 1:
The resin layer is applied with locally optimized properties: it provides rigid support and gap filling at the interfaces between the armature winding and winding holding member to ensure positional stability, while maintaining thermal conductivity in the radial direction to enable effective heat dissipation. This local quality differentiation resolves the contradiction between stability and heat dissipation.
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
The solution effectively reduces positional displacement and deformation of the armature winding, enhances heat dissipation, and maintains the armature winding's position without resin leakage, thereby improving the rotary electric machine's performance.
Implementation Method 1
The resin is interposed between the winding holding member and the cylindrical covering member
Implementation Method 2
The cylindrical covering member covers a facing portion of the armature winding that faces the field element in the radial direction
Implementation Method 3
The field element has magnetic poles, and the armature has a toothless structure. The armature includes a multiphase armature winding. The field element and the armature face each other in a radial direction of the rotary electric machine
Data Source
AI summary
A rotary electric machine includes a field element having magnetic poles, and an armature having a toothless structure. The armature includes a multiphase armature winding. The field element and the armature faces each other in a radial direction. A winding holding member has a cylindrical shape, and the armature winding is attached to the winding holding member such that conductor portions of the armature winding are arranged in a circumferential direction. A cylindrical covering member has a cylindrical shape and covers the conductor portions of the armature winding. The conductor portions of the armature winding are interposed between the winding holding member and the cylindrical covering member. A resin is interposed between the winding holding member and the cylindrical covering member. The cylindrical covering member covers a facing portion of the armature winding that faces the field element in the radial direction.