Wave Winding Coil Transposition via Inclined Parts
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Solution Overview
Problem
Existing methods for manufacturing wave winding coils with continuous wires face challenges in forming transposed configurations without changing the folding method, leading to difficulties in achieving balanced electrical phases and reducing circulating currents.
Innovation Solution
A method involving the formation of transposition shapes with U-shaped parts of continuous wires, where one U-shaped part is disposed inside another, and the creation of inclined parts to facilitate folding, allowing for the formation of transposed wave winding coils with continuous wires without altering the folding method, enabling efficient phase alignment and reduced circulating currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If transposition shapes are formed on both upper and lower surfaces of the stator core to achieve coil transposition, then circulating current is suppressed and electrical balance is improved, but the manufacturing complexity increases and continuous wire folding becomes difficult
Solution Approach 1:
The invention extracts the transposition function from the stator core structure and relocates it to the coil winding process itself. By forming transposition shapes only on the upper surface and using inclined parts to achieve the transposition effect during folding, the complex alternating transposition/non-transposition pattern on both surfaces is eliminated, simplifying manufacturing while maintaining electrical balance
Solution Approach 2:
The invention performs preliminary formation of transposition shapes and inclined parts on the continuous wire before the final folding process. This allows the transposition configuration to be established in advance, enabling continuous wire folding without requiring complex real-time adjustments during the winding process
2Loss of energy
If alternating transposition and non-transposition shapes are formed on the stator core surfaces, then coil transposition is achieved to suppress circulating current, but the folding method must be changed repeatedly making continuous wire manufacturing difficult
Solution Approach 1:
The invention segments the transposition function into two distinct components: transposition shapes formed on the upper surface and inclined parts that facilitate the transposition during folding. This segmentation allows each component to perform its specific function independently, enabling continuous wire manufacturing without repeated changes to the folding method while still achieving the necessary coil transposition to suppress circulating current
3Device complexity
If parallel winding wires are used to form wave winding coils, then the coil structure is simple, but electrical imbalance occurs leading to circulating current and energy loss
Solution Approach 1:
The invention uses the nested doll principle by placing one U-shaped part inside another U-shaped part to form the transposition configuration. This nested arrangement achieves the necessary phase transposition for electrical balance while maintaining a relatively simple overall coil structure, preventing circulating current without excessive complexity
Data Source
AI summary
The continuous wires respectively have U-shaped parts and straight parts. The method includes: a transposition shape forming step of forming transposition shapes in each of which, among at least the two continuous wires belonging to an identical phase, the U-shaped part of one of the continuous wires is disposed inside the U-shaped part of the other one of the continuous wires; an inclined part forming step of causing the pairs of straight parts of the continuous wires respectively formed with the transposition shapes to be offset to form inclined parts on the continuous wires; and a folding step of folding the continuous wires formed with the inclined parts to form the turning parts and the slot disposition parts. The inclined part forming step and the folding step are alternately performed.