Pre-Assembled Winding Spacer for Automated Cooling Channel Assembly
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Solution Overview
Problem
Existing spacer elements for windings in electric devices require individual placement of ribs to define flow channels, leading to increased manufacturing time and effort, and there is a need for improved spacer elements that facilitate automation and enhance cooling efficiency.
Innovation Solution
A spacer element comprising connection members and ribs that are pre-assembled to form multiple flow channels, allowing for simultaneous placement between winding units, reducing manufacturing time and enabling automation, while providing enhanced cooling and support for the winding units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If ribs are individually placed to define flow channels, then flow channel definition is achieved, but manufacturing time increases
Solution Approach 1:
Multiple ribs that individually define flow channels are merged into a single pre-assembled spacer element. This integration allows the entire spacer element with multiple flow channels to be placed between winding units in one step, eliminating the need for individual rib placement and significantly reducing manufacturing time and assembly complexity.
Solution Approach 2:
The ribs are pre-assembled into a complete spacer element structure before being introduced to the winding process. This preliminary assembly of multiple ribs into a unified component enables automated placement and reduces on-site assembly steps during winding manufacturing.
2Productivity
If multiple ribs are pre-assembled into a spacer element, then manufacturing time is reduced and automation is enabled, but structural complexity increases
Solution Approach 1:
The spacer element is designed as a modular structure with multiple ribs segmented into distinct flow channel regions. This segmentation allows each rib to perform its specific flow channel definition function while the overall modular design enables standardized manufacturing and automated handling, balancing structural complexity with productivity gains.
3Temperature
If a compound of ribs defining multiple flow channels is used, then cooling efficiency is improved, but material usage increases
Solution Approach 1:
The spacer element serves multiple functions simultaneously: it provides structural support between winding units, defines multiple flow channels for cooling fluid distribution, and acts as an insulating barrier. This multi-functionality allows a single component to deliver enhanced cooling efficiency without requiring additional separate components, thereby avoiding proportional increases in material consumption.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The spacer element reduces manufacturing time, facilitates automation, improves cooling efficiency, and optimizes the distribution of cooling fluid, while offering material savings and better short-circuit force distribution.
Implementation Method 1
Each two adjacent ribs delimit a flow channel for a cooling fluid, said flow channel extends between and along the two adjacent ribs
Data Source
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AI summary
According to an embodiment, the spacer element (1) for a winding (100) of an electric device comprises at least one connection member (20, 21, 22) and a plurality of ribs (3). The ribs are connected to the connection member and are spaced from each other pairwise. The spacer element is arrangeable between two successive winding units (10) of the winding during manufacturing of the winding. Each two adjacent ribs delimit a flow channel (4) for a cooling fluid, said flow channel extends between and along the two adjacent ribs.