Twisted Welded Conducting Wire for Rotary Machine Winding
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Solution Overview
Problem
The existing assembly conducting wires for rotary electric machines face issues with circulating currents and wire separation when bent for winding, leading to increased losses and potential insulation fractures.
Innovation Solution
The assembly conducting wire is designed with wires twisted and welded at specific intervals, both inside and outside the slot, to inhibit circulating currents and prevent wire separation, utilizing a twisting method that reverses the direction of eddy currents and secures the wires with welds at dislocation points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the assembly conducting wire is bent with large bending curvature for winding, then the wire can be formed into stator coil shape, but the wires that form the strand wire come apart and the outermost insulating layer fractures
Solution Approach 1:
The wires are welded together at predetermined intervals before the winding process. This preliminary welding action secures the wires to each other, preventing them from coming apart during the subsequent bending and winding operations, thus maintaining binding integrity while achieving the required coil shape
Solution Approach 2:
The assembly conducting wire is divided into multiple individual wires that are twisted together. This segmentation allows each wire to be independently secured through welding at specific intervals, providing localized reinforcement that prevents wire separation during bending while maintaining the overall flexibility needed for winding
2Strength
If metal material is used as the coating of the outer layer to strengthen the banding of the strand wire, then the binding strength increases, but an eddy current is generated in the metal material layer which increases loss
Solution Approach 1:
The harmful metal coating layer that causes eddy currents is completely removed from the outer surface of the assembly conducting wire. Instead, the binding strength is achieved through welding the individual wires together at predetermined intervals, separating the binding function from the outer coating and eliminating the source of eddy current losses
Solution Approach 2:
The invention converts the potential harm of metal coatings (eddy current generation) into a benefit by using welding to achieve binding strength. The welding process provides the necessary mechanical strength to prevent wire separation during bending, while simultaneously eliminating the eddy current problem that would be caused by metal outer coatings
3Strength
If the wires are welded together at suitable locations to prevent wire separation, then the binding strength improves, but the path of the circulating current lengthens and loss increases
Solution Approach 1:
Welding is applied selectively at predetermined intervals rather than continuously along the entire length of the wires. This local welding approach provides sufficient binding strength to prevent wire separation during bending, while minimizing the total welding area and thus reducing the impact on circulating current paths and associated losses
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 design effectively reduces circulating current losses and prevents wire separation, maintaining insulation integrity and improving the efficiency and reliability of rotary electric machine windings.
Implementation Method 1
The plurality of wires are welded together at a predetermined distance
Implementation Method 2
an eddy current will be generated in the metal material layer, and this eddy current will become a circulating current which will increase loss when it flows
Data Source
AI summary
An assembly conducting wire for a rotary electric machine winding includes a plurality of bundled wires, the plurality of wires being twisted in a circumferential direction of the assembly conducting wire, and the plurality of wires being welded together at a predetermined distance.