Rotary Machine Winding Fixing Turn for Wire Stability
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Solution Overview
Problem
Existing winding arrangements for electrical machines are prone to sections of winding wire slipping or coming loose during production, assembly, or operation, potentially leading to mechanical blockages, and existing solutions increase material costs and complexity.
Innovation Solution
A winding arrangement featuring a fixing winding with transversely placed turns across the coil head of the last-wound coil, which is integrated into the winding scheme, ensuring secure fixation without additional means, and the fixing turns can run at an angle across multiple slots to enhance retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional means such as threads or tapes with impregnation resin are used to fix winding wire, then winding wire stability is improved, but material costs and assembly complexity increase
Solution Approach 1:
The winding wire itself is used to create the fixing turn that secures the coil head, eliminating the need for separate fixing components. The winding process naturally produces the fixing structure through the self-service mechanism where the conductor serves both as the functional winding element and the securing element.
Solution Approach 2:
The fixing function is merged with the winding conductor itself rather than being a separate component. The same winding wire that carries electrical current is also used to form the fixing turn that mechanically secures the coil, combining multiple functions into a single element.
2Reliability
If additional means such as threads or tapes with impregnation resin are used to fix winding wire, then winding wire stability is improved, but material costs increase
Solution Approach 1:
The winding wire performs the dual function of electrical conduction and mechanical fixation, eliminating the need for additional materials such as threads, tapes, or impregnation resin. This self-service approach reduces material quantity and cost while maintaining fixation reliability.
Solution Approach 2:
Instead of discarding excess winding wire or using separate fixing materials, the invention recovers and utilizes the winding wire itself to create the fixing turn, maximizing the utility of the already-present material and eliminating waste.
3Reliability
If the winding scheme includes fixing turns formed by the winding conductor, then winding wire fixation is improved, but winding process complexity increases
Solution Approach 1:
The winding process automatically generates the fixing turn as an integral part of the winding sequence, requiring no separate fixation steps. The winding machine performs the entire operation using the same conductor and process parameters, maintaining ease of manufacture while achieving reliable fixation.
Solution Approach 2:
The fixing operation is merged with the winding operation into a single continuous process. The same winding head, same conductor feed, and same tension control system handle both the functional winding and the securing fixing turn, eliminating the need for separate manufacturing steps.
Data Source
AI summary
A winding arrangement in a machine component for a rotary electrical machine (1), comprising:a plurality of slots (11);a winding (7) which is wound with a winding conductor (8) and has a plurality of coils (12) which each run through two of the slots (11), wherein coil sides, which are accommodated in the slots (11), of at least one last-wound coil (16) are exposed toward corresponding slot openings of the slots (11); andat least one fixing winding (17, 20a, 20b) which is formed by a section of the winding conductor (8) and has at least one fixing turn which runs transversely across a coil head (14) of the at least one last-wound coil (16) of the winding (7).