Trapezoidal Coil Layout for Dense Polyphase Windings
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Solution Overview
Problem
Existing winding designs for electric machines and linear motors often result in low volume filling efficiency due to disorderly winding methods and the requirement for multiple coil types, complicating the assembly process.
Innovation Solution
A general-purpose winding coil shaped as an equilateral trapezium, manufactured using self-baking wire, with straight active elements and arc-bent or straight coil ends, allowing for dense packing and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the to-and-fro method is used to form coils, then the coil can be manufactured, but the degree of filling the volume for the coil wire is low
Solution Approach 1:
The coil wire is pre-formed into a trapezoidal shape with predetermined geometry before assembly. The active elements and coil ends are shaped in advance to achieve optimal packing configuration, eliminating the need for disorderly winding during assembly and maximizing volume filling efficiency.
Solution Approach 2:
The coil geometry is changed from conventional circular or rectangular shapes to a specific trapezoidal configuration with defined parameters (acute angle α, dimensions h, d, ht). This parameter optimization enables denser packing arrangements and improves the degree of filling the volume for the coil wire.
2Ease of manufacture
If coils of two types (straight and oblique) are used to form windings, then the winding can be manufactured, but the device complexity increases
Solution Approach 1:
A single universal coil design with trapezoidal geometry is created that can be used for all phases and positions in the winding. This general-purpose coil replaces the need for separate straight and oblique coil types, simplifying inventory, assembly, and manufacturing while maintaining full winding manufacturing capability.
Solution Approach 2:
All coils in the winding are made identical in shape and dimensions, creating a homogeneous set of components. This uniformity eliminates the complexity of managing and assembling multiple coil types, while the trapezoidal design provides the necessary adaptability for different winding configurations.
3Ease of operation
If preformed windings with trapezoidal coils are used, then the coil ends can be positioned in two planes, but the degree of filling the volume for the coil wire is low
Solution Approach 1:
The coil ends are designed to extend in multiple spatial dimensions, allowing positioning in two planes while optimizing the three-dimensional packing arrangement. The trapezoidal geometry with specific acute angles enables the coil ends to occupy space more efficiently across multiple planes, simultaneously achieving ease of positioning and high volume filling.
Data Source
AI summary
The technical solution relates to the field of electromechanical engineering and can be used in the manufacture of windings for rotating electrical machines (electric motors and electric generators) with or without slots, or for linear electric motors. A coil for manufacturing a polyphase winding for an electrical machine is made in the shape of an isosceles trapezoid from a self-sintering conductor. The active elements of the coil are straight, and the overhangs of the coil are bent at a right angle to the active elements of the coil and are curved along an arc of a circle in the case of rotating electrical machines or are straight in the case of linear electric motors. The dimensions of the trapezoid are determined by the width of the active element of the coil, the width of a tooth of the core, the thickness of the coil and the acute angle of the trapezoid.