Wave-Shaped Coil Wire Braiding Spacing
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Solution Overview
Problem
Conventional methods for braiding coil wires in rotating electrical machines often result in insufficient spacing between coil wire bunches, leading to interference, deformation, and the formation of awkward coil assemblies due to insufficient braiding spacing and the need for a restoring process.
Innovation Solution
The coil wires are designed with a wave-shaped configuration, featuring straight portions and kinked portions that maintain adequate spacing between coil wire bunches, preventing deformation and the need for a restoring process by ensuring proper alignment and secure braiding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional braiding methods are used with closely spaced coil wire bunches, then the number of coil wires can be increased, but the spacing becomes insufficient leading to interference and deformation
Solution Approach 1:
The patent introduces a new spatial dimension by forming wave-shaped configurations in the coil wires. The wave shape creates additional spacing in the axial direction while maintaining the same number of coil wires, effectively resolving the spacing problem without reducing the quantity of coil wires.
Solution Approach 2:
The patent changes the geometric parameters of the coil wire configuration by introducing wave-shaped formations with specific wavelengths and amplitudes. This parameter change increases the effective spacing between adjacent coil wires, preventing interference and deformation while maintaining the required number of wires.
2Object-affected harmful factors
If the spacing between coil wire bunches is expanded, then interference is reduced, but the aligned condition of coil wires must be broken requiring a restoring process
Solution Approach 1:
The patent applies preliminary action by pre-forming the coil wires into wave-shaped configurations before the braiding process. This preliminary shaping ensures that adequate spacing is maintained throughout the braiding operation, eliminating the need for subsequent restoring processes to fix alignment issues.
3Volume of moving object
If closely spaced coil wire bunches are braided, then the coil assembly can be compact, but the braiding process becomes difficult and deformation occurs
Solution Approach 1:
The patent employs curvature by forming wave-shaped configurations in the coil wires. This curvature creates natural spacing between adjacent wires, making the braiding process easier to execute while maintaining a compact overall coil assembly volume. The wave shape allows smooth routing during braiding without sharp angles that would cause deformation.
Data Source
AI summary
A coil wire for a coil assembly of a rotating electrical machine is provided such that sufficient space in braiding is secured when coil-wire-bundles bundling a plurality of the coil wires are braided. Each of the coil wires has a predetermined length, a plurality of straight portions and a plurality of turn portions, the straight portions linearly-extend in parallel in a first direction substantially perpendicular to the overall length direction of the coil wires, the turn portions connect two of the straight portions to be adjacent via first-kinked-portions and second-kinked-portions, the first-kinked-portions are kinked in a second direction substantially perpendicular to both the first direction and the length direction of the coil wires, the second-kinked-portions are kinked in a third direction substantially opposite to the second direction so that the turn portions are formed in a wave-shape in the length direction of the coil wires.