Winding Overhang Grooves for Elevator Motor Wire Routing
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Solution Overview
Problem
Elevator motor winding overhangs face challenges in easy formation and high risk of electric short circuits due to wire crossings, which complicates manufacturing and reduces reliability.
Innovation Solution
A cylindrical winding overhang with grooves and openings of varying heights allows for neat wire arrangement and automated winding formation, preventing wire crossings and reducing the risk of short circuits by guiding wires through specific slots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wires are arranged freely on the winding overhang, then the winding process is simple, but wire crossings occur causing electric short circuits
Solution Approach 1:
The winding overhang is segmented into multiple grooves of different heights, with each groove designed to receive specific wires. This segmentation prevents wire crossings by providing dedicated pathways for each wire, thereby eliminating the risk of electric short circuits while maintaining a structured yet manageable design.
Solution Approach 2:
Different regions of the winding overhang are given different local qualities through varying groove heights. Each groove's height is specifically tailored to accommodate particular wires, ensuring proper wire arrangement and preventing crossings in critical areas without requiring complex structures throughout the entire overhang.
2Productivity
If manual winding method is used, then flexibility is high, but production efficiency is low and costs are high
Solution Approach 1:
The winding overhang is pre-configured with grooves of specific heights before the winding process begins. This preliminary arrangement of grooves guides the automated winding machine to place wires correctly without requiring complex real-time control, thereby improving productivity while keeping the manufacturing process relatively simple.
Solution Approach 2:
The groove structure itself serves the function of guiding and positioning wires during the winding process. The varying heights of the grooves automatically ensure proper wire arrangement and prevent crossings, allowing the winding overhang to assist the automated process without requiring additional complex guiding mechanisms.
3Manufacturing precision
If uniform groove heights are used, then manufacturing is simple, but wire arrangement is messy and crossings occur
Solution Approach 1:
The groove heights are varied locally according to the specific requirements of different wires. This local differentiation in groove heights ensures precise wire arrangement and prevents crossings, while the overall groove structure remains relatively simple to manufacture, requiring only controlled variations in height rather than complex three-dimensional shaping.
Solution Approach 2:
The height parameter of the grooves is changed systematically to accommodate different wires. By varying this single parameter (height) in a controlled manner, the patent achieves precise wire arrangement and prevents crossings without introducing excessive manufacturing complexity, as other groove parameters such as width and depth can remain uniform.
Data Source
AI summary
A winding overhang (20) configured for supporting windings of an electric motor (40) comprise a cylindrical wall (22) extending around a center axis (A). The cylindrical wall (22) includes a plurality of grooves (28a-28e) formed along the circumference (37, 38) of the cylindrical wall (22), each groove (28a-28e) having a constant width (W) along the circumference (37, 38); and a plurality of openings (26) having different heights (H1, H2, H3, H4, H5). Each opening (26) extends from an end surface (36) of cylindrical wall (22) and allows a wire (30a-30c) to pass between an outer area (34) outside the cylindrical wall (22) and an inner space (32) defined by the cylindrical wall (22).