Electric Machine Active Part with V-Shaped Winding Overhang
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Solution Overview
Problem
Existing electric machine designs have inefficiencies in the winding overhang region, leading to increased space, weight, and losses due to unnecessary conductor length and projection, which hinders the compactness and efficiency of the machine.
Innovation Solution
The design features a tiered winding with coils arranged at 0°, 45°, and 90° inclinations, forming a V shape in the winding overhang region, with each coil divided into two parts for independent insulation, minimizing conductor length and optimizing the winding overhang to reduce weight and losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional winding overhang designs are used with coils projecting from the carrier part, then the coils can be easily arranged in grooves, but the conductor length and projection increase leading to unnecessary space requirements, weight and losses
Solution Approach 1:
The coil is divided into multiple segments: the main winding portion arranged in the groove and the winding overhang portion projecting from the carrier part. This segmentation allows the coil to be optimally positioned in the groove while minimizing the unnecessary projection, thereby reducing conductor weight without compromising ease of arrangement.
Solution Approach 2:
The invention optimizes the parameters of the winding overhang by minimizing its projection length and adjusting its orientation. By changing the geometric parameters of the overhang region, the design reduces the unnecessary conductor length while maintaining the functional requirements of the coil arrangement.
2Ease of manufacture
If coils project from the end faces of the carrier part forming a winding overhang, then the coil windings can be completed, but the projection increases space requirements and does not contribute to torque formation
Solution Approach 1:
The invention extracts and minimizes the non-functional portion of the coil (the excessive projection of the winding overhang) while retaining the essential winding structure needed for coil completion. This allows the coil to be properly formed without the unnecessary volume occupation.
Solution Approach 2:
The geometric parameters of the winding overhang are optimized by reducing its projection length and adjusting its orientation relative to the carrier part. This parameter optimization reduces the volume occupied by the overhang while maintaining sufficient space for coil winding completion.
3Ease of manufacture
If the winding overhang projection is increased to accommodate coil arrangements, then coils can be properly formed, but weight and losses increase due to unnecessary conductor length
Solution Approach 1:
The coil structure is segmented into the functional winding portion and the non-functional overhang portion. This segmentation enables precise control over where the conductor is needed (in the groove for torque formation) and where it can be minimized (the overhang projection), thereby reducing conductor losses.
Solution Approach 2:
The invention optimizes the parameters of the winding overhang by minimizing its projection length and adjusting its orientation. By changing these geometric parameters, the design reduces the unnecessary conductor length in the overhang region, thereby reducing resistive losses while maintaining adequate space for proper coil formation.
Data Source
AI summary
An active part of an electric machine includes a plurality of coils, each having a sub-conductor. The coils are formed by windings of the sub-conductors thereof. The windings of a coil each have a predetermined winding length. In addition, the active part has a carrier part, in the grooves of which, the coils are arranged. The coils have a winding head region which projects from an end surface of the carrier part. The coils are also arranged in the form of a tiered winding. At least one of the coils has a V-shaped cross-section in the winding head region, as a result of an arrangement of its sub-conductor.