Wave Coil Winding Former for Cylindrical Motor Windings
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing coil windings result in frustoconical geometries due to changing radii with each layer, which inefficiently use axial space in electric motors, reducing power density.
Innovation Solution
A method involving a winding former with multiple sections of varying widths allows for continuous wave winding production, compensating for radius changes and achieving cylindrical geometries, enabling efficient use of axial space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wave winding is produced by helically winding conductor wire around a flat winding former with constant width, then continuous winding can be achieved, but the radius changes with each layer causing frustoconical geometry
Solution Approach 1:
The winding former is divided into multiple winding sections along its longitudinal axis, where each section has a different winding width. This segmentation allows the winding width to vary continuously or in steps across different sections, enabling compensation for the radius change that occurs with each wave winding layer. The conductor wire is fed through different winding sections as the winding progresses, maintaining a constant outer diameter and cylindrical geometry of the final coil winding.
Solution Approach 2:
Different sections of the winding former have different local properties (winding widths) tailored to specific requirements. The first winding section has a different width than the second winding section, allowing each local region to contribute to compensating the radius change at different stages of the winding process. This local variation in width ensures that the overall geometry remains cylindrical despite the multi-layer construction.
2Ease of manufacture
If winding width is kept constant across all layers, then manufacturing is simplified, but axial space is wasted due to frustoconical geometries
Solution Approach 1:
The winding width parameter is changed across different sections of the winding former. Instead of maintaining a constant width, the width varies from one winding section to another, with each section's width specifically chosen to compensate for the radius change at that layer. This parameter variation enables the wave winding to maintain a constant outer diameter, maximizing axial space utilization and achieving cylindrical geometry without significantly complicating the manufacturing process.
3Shape
If multiple winding sections with different widths are used, then cylindrical geometry is achieved, but winding former complexity increases
Solution Approach 1:
The winding former is segmented into multiple sections with different winding widths, where each section serves a specific function in compensating for radius changes. The segmentation is implemented in a systematic way that, while increasing structural complexity, provides the necessary control over the winding geometry to achieve the desired cylindrical shape and maximize space utilization.
Solution Approach 2:
Each winding section has a specific local width property tailored to its position and the requirements of that particular layer. This local differentiation in width allows precise control over the winding geometry, enabling cylindrical shape achievement while the overall structure remains relatively simple and manufacturable.
Data Source
AI summary
The invention relates to a method for producing a wave winding for forming a coil winding (30) with at least one wave winding layer (33a, b) in a stator or rotor element (100), wherein a winding former (10) is provided with at least two winding sections (13a, b, c) and such that it can be rotated about a longitudinal axis (11), comprising the following method steps: Applying parallel coil wires to a first side (15) of the winding former (10) in a winding section (13) of the winding former (10); forming winding heads (31a, b) by alternately axially shifting the parallel coil wires on the winding former (10) and winding same about the rotated winding former (10); repeating steps a and b until the wave winding has reached a length of a first wave winding layer (33a) of the coil winding (30), wherein, according to the invention, the steps a to c are repeated in another winding section (13b) with a different winding width (12b). The invention also relates to a winding former (10) for producing a wave winding of this type which is suitable for introduction into grooves of a stator or rotor element (100).