Wave Winding Method for Radially Narrow Stator Coil Heads
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Solution Overview
Problem
Concentric windings in stators or rotors result in voluminous and radially thick winding heads, which occupy excessive space, especially when using round wire, making it challenging to achieve a radially narrow arrangement of winding heads in stator or rotor slots.
Innovation Solution
A method where parallel wires are wound onto a rotatable former, with fillets formed and head portions shaped to be displaced axially, allowing the winding to be pressed flat and arranged in a wave pattern, creating a distributed winding with radially narrow heads that can be efficiently aligned into stator or rotor slots, using a striplike coil holder and transfer tool for precise placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If concentric windings are formed by winding up onto a former, then the winding can be produced with standard manufacturing processes, but the winding heads become voluminous and radially thick
Solution Approach 1:
The patent transitions from conventional concentric winding arrangement to a wave winding arrangement where fillets are distributed along the axial dimension rather than being concentrated radially. The winding heads are arranged in a wave pattern with fillets extending axially, converting radial thickness into axial length, thereby achieving radially narrow winding heads while maintaining manufacturability through modified winding processes
2Ease of manufacture
If conventional concentric windings are used, then the manufacturing process is simple, but the winding heads occupy excessive radial space in stator or rotor slots
Solution Approach 1:
The invention redistributes the winding head volume from the radial dimension to the axial dimension by forming wave-shaped windings. The fillets are arranged to extend axially along the former, creating a compact radial profile while maintaining the necessary wire length and electrical connections through the wave pattern geometry
Solution Approach 2:
The patent modifies the geometric parameters of the winding arrangement by changing from concentric circles to wave patterns with specific amplitudes and wavelengths. This parameter change allows the winding heads to be compressed radially while extending axially, achieving the desired radial narrowness without compromising the electrical functionality
Data Source
AI summary
A method for producing a pattern of coil windings in which each coil turn has one fillet each in two slots, and the two fillets are joined by a head portion. A plurality of coil turns are made simultaneously by winding n parallel wires with intermediate spacing onto a rotatable former. To obtain small winding heads, there is a repeating of: a laying work step where one fillet and the wire length of one head portion are laid on the former; and a displacing work step where the resultant fillets together with the adjoining first end of the respective associated head portions, and the wire guide together with the second end of these head portions, are displaced relative to one another along the former by n times the intermediate spacing of the wires. Next, the winding is removed from the former, and pressed flat.