Electrical Machine Winding Guide Element for Uniform Coil Lengths
Solution Overview
Problem
The existing methods for manufacturing winding systems in electrical machines result in varying mean coil lengths and electrical resistances due to differences in the deflection path length at the end sides, leading to inefficiencies and increased material usage.
Innovation Solution
The introduction of a guide element on the end sides that allows for controlled winding and insertion of electrical conductors, secured by an end plate with axially protruding separating elements, ensuring precise and uniform winding with identical subwinding turn lengths and resistances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If subsequent subwindings are introduced into the stator laminate stack, then the winding system can comprise multiple subwindings, but the deflection path length at the end sides increases leading to varying mean coil lengths and electrical resistances
Solution Approach 1:
A guide element is introduced as an intermediary component between the electrical conductors and the end plate. This guide element defines a controlled deflection path for the electrical conductors at the end sides, ensuring that subsequent subwindings follow the same geometric path as the first subwinding. The guide element acts as a mediator that maintains consistent mean coil lengths and electrical resistances across all subwindings, resolving the precision problem while enabling multi-subwinding capability.
2Productivity
If the deflection path length at the end sides is increased to accommodate multiple subwindings, then more subwindings can be introduced, but the mean coil lengths and material usage increase
Solution Approach 1:
The guide element changes the geometric parameters of the deflection path at the end sides. By providing a controlled and optimized path through the guide element, the mean coil length is reduced compared to conventional designs without such guidance. This parameter change allows multiple subwindings to be accommodated while minimizing material usage, as the electrical conductors follow a more efficient path defined by the guide element's geometry.
3Manufacturing precision
If guide elements are used to control the winding path, then manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The guide element is positioned locally at the end sides of the stator laminate stack, specifically where the electrical conductors need deflection control. Rather than complicating the entire winding system, the guide element provides localized guidance only at the critical end regions. This local application of the guiding function achieves the necessary manufacturing precision for uniform mean coil lengths and electrical resistances while minimizing the overall device complexity.
Data Source
AI summary
An electrical machine includes a basic bed having a opposite axial end sides and slots, wherein the slots an the end sides have each a slot end opening. A winding system has electrical conductors which are accommodated in the slots wherein the electrical conductors extend out on one of the end sides of at least one of the slot end openings. The electrical conductors are hereby laid within a bridging region extending in a circumferential direction on the at least one end side and are inserted into at least one other one of the slot end openings. Arranged on the at least one end side in the bridging region is a first guide element for guiding the electrical conductors of a first subwinding of the windings stem. An end late is arranged on the at least one end side and has at least one axially protruding separating element with the first guide element having a base bearing a against the separating element.