Winding Head Clamps for Electrical Machine Stability
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Solution Overview
Problem
Electrical machines face challenges in maintaining high power density due to resilience issues in winding overhangs, which lead to increased size and reduced efficiency over time, and existing solutions like bandaging are costly, time-consuming, and difficult to automate.
Innovation Solution
The use of clamps accommodated in bead-like indentations on the winding overhang surface to stabilize and secure the end windings, reducing the need for bandaging and minimizing space requirements while preventing springing open.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If bandaging is used to fix the winding overhang, then the resilience behavior is improved, but the production cost and time increase
Solution Approach 1:
The patent extracts the essential function of bandaging (securing the winding overhang) and implements it through a simplified clamp mechanism. The clamp is a discrete component that can be easily installed without the complex bandaging process, thereby maintaining stability while improving productivity.
Solution Approach 2:
The clamp is designed as a simple, inexpensive component that can be easily manufactured and replaced if necessary. This contrasts with the more complex and costly bandaging process, allowing for faster production and easier automation.
2Stability of the object's composition
If bandaging is used to fix the winding overhang, then the resilience behavior is improved, but the production complexity increases
Solution Approach 1:
The complex bandaging process is replaced by a simple clamp mechanism that performs the same essential function of securing the winding overhang. The clamp's simple structure and easy installation significantly reduce production process complexity.
Solution Approach 2:
The patent changes the physical state and properties of the fixing mechanism from a flexible bandage requiring manual wrapping to a rigid clamp that can be mechanically installed. This parameter change simplifies the production process and enables automation.
3Reliability
If sufficient free space is left to prevent springing, then the winding safety is improved, but the power density decreases
Solution Approach 1:
The clamp is installed on the winding overhang before the machine is fully assembled and before any springing can occur. This preliminary action secures the winding in its pressed position, allowing the machine to be compact without risk of future springing damage.
Solution Approach 2:
The clamp provides a counteracting force against the springing tendency of the winding overhang. By applying this preliminary anti-action, the winding is held firmly in place, eliminating the need for excessive clearance and enabling higher power density.
4Power
If the winding overhang is pressed to reduce height, then the power density is improved, but the springing effect increases
Solution Approach 1:
The clamp is installed on the pressed winding overhang immediately after pressing, while the winding is still in its compressed state. This preliminary action locks in the pressed configuration and prevents the winding from springing back, thereby maintaining both high power density and stability.
Solution Approach 2:
The clamp applies a counteracting force to the springing tendency that arises after pressing. This preliminary anti-action ensures that the winding remains in its pressed, compact configuration, maintaining both high power density and structural stability over time.
Data Source
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AI summary
The invention relates to an electrical machine having a stator (1) and at least one winding (2), wherein the at least one winding (2) is formed of a coil-shaped arrangement of an electrical conductor and is mounted to the stator (1) and at an end surface of the stator (1) forms a winding head (5), which on the end wall of the winding head (5) facing away from the stator (1) has a winding head surface (9). The electrical machine is characterized in that the winding head surface (9) has recesses (11), and that clamps (13) are provided on the winding head (5), which encompass the winding head surface (9), wherein the clamps (13) are each accommodated in one of the recesses (11), at least in some areas. The clamps (13) can avoid a spring action of the previously pressed winding head (5) to a large extent. Since the clamps (13) are at least partially accommodated in the recesses (11), a construction space can be reduced as compared to traditional solutions, in which the winding heads (5) were bandaged, thus increasing a power density of the electrical machine.