Wound Field Rotor Winding Layout for Higher Space Factor

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Existing wound field rotors face challenges in maximizing the space factor of the field winding due to interference between adjacent main pole portions, leading to reduced space utilization and increased dead space.

Innovation Solution

The field winding is configured with straight portions having a rectangular cross-section, where the inner side dimensions are smaller than the outer side dimensions, allowing for increased turns and reduced interference, thereby enhancing the space factor and reducing resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the field winding is wound in multiple layers around each main pole with uniform straight portion dimensions, then the winding structure is simple and easy to manufacture, but the space factor is reduced due to interference between adjacent main pole portions and increased dead space

Engineering Contradiction:
Improvewinding structure simplicityVSAvoidspace factor
Core Design Contradiction:
Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent applies local quality by making the straight portion dimensions variable rather than uniform. Specifically, the straight portions on the inner side in the radial direction have smaller dimensions in the circumferential direction compared to those on the outer side. This local differentiation optimizes space utilization in different radial zones, reducing dead space and increasing the space factor while maintaining manufacturability.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent employs asymmetry by creating non-uniform straight portion dimensions across the radial direction. The inner straight portions are designed with smaller circumferential dimensions than outer straight portions, breaking the symmetry of traditional uniform windings. This asymmetric design effectively reduces interference between adjacent main pole portions and maximizes the use of available space, thereby increasing the space factor.

Inventive Principle:
Principle #4Asymmetry

2Reliability

If the number of turns is increased to enhance excitability, then the field winding performance improves, but the interference between adjacent main pole portions increases and dead space increases

Engineering Contradiction:
ImproveexcitabilityVSAvoidinterference and dead space
Core Design Contradiction:
ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent uses local quality to increase the number of turns specifically on the inner side in the radial direction where space is more constrained. By making straight portions on the inner side smaller in the circumferential direction, the design allows for more turns to be packed in this region without causing excessive interference with adjacent main pole portions, thus enhancing excitability while controlling dead space.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent addresses the turn density issue by introducing dimensional variation in the radial direction. Instead of uniformly increasing turns throughout, the design varies the straight portion dimensions across the radial dimension, allowing optimized turn distribution. This dimensional approach enables increased excitability through more turns while managing interference by strategically placing turns in radial zones with appropriate spacing.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

3Ease of manufacture

If uniform straight portion dimensions are used throughout the radial direction, then the manufacturing process is simplified, but dead space increases and space utilization is reduced

Engineering Contradiction:
Improvedimensional consistencyVSAvoidspace utilization
Core Design Contradiction:
Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent resolves this contradiction by implementing local quality through radially-variable straight portion dimensions. The inner straight portions have smaller circumferential dimensions than outer straight portions, creating a locally optimized structure that reduces dead space and improves space utilization. This localized dimensional variation maintains reasonable manufacturing complexity while significantly enhancing space efficiency.

Inventive Principle:
Principle #3Local quality

Data Source

PatentUS20250392176A1Wound field rotor and method for manufacturing wound field rotor
Publication Date: 2025.12.25 DENSO CORP
  • US20250392176A1 patent drawing
  • US20250392176A1 patent drawing
  • US20250392176A1 patent drawing

AI summary

A wound field rotor includes a rotor core including a main pole portion and a field winding configured by a conductor wire wound in multiple layers around each main pole portion. The field winding includes a straight portion extending in an axial direction along a side surface in a radial direction of the main pole portion and a crossover portion connecting end portions of the straight portions. A lateral cross-section of the straight portion has a rectangular shape. The field winding is configured such that, of the straight portions arrayed in a circumferential direction and a radial direction in the main pole portion, a dimension in a short-side direction of the lateral cross-section of the straight portion on an inner side in the radial direction is smaller than the dimension in the short-side direction of the lateral cross-section of the straight portion on an outer side in the radial direction.