Alternator Field Coil Connection Structure
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Solution Overview
Problem
Conventional vehicle alternators face issues with electrical short circuits and corrosion due to ultrasonic welding, exposure of field coils, and difficulties in automating the assembly of insulator tubes, leading to defects and increased costs.
Innovation Solution
A connection structure and method for field coils and lead wires in a vehicle alternator that uses guide grooves and protrusion hubs with epoxy curing to secure twisted parts within guide pockets, eliminating the need for insulator tubes and reducing exposure, thereby preventing corrosion and improving durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding is used to connect lead wires and field coils, then electrical connection is achieved, but lead wires are released and short circuits occur due to vibration impact
Solution Approach 1:
The patent applies preliminary action by forming twisted parts between the lead wire and field coil before welding. The twisting creates a mechanical interlock that prevents lead wire release during vibration, while the subsequent welding secures the electrical connection. This preliminary mechanical preparation resolves the contradiction between connection reliability and strength.
2Object-affected harmful factors
If insulator tubes are assembled with field coils to prevent corrosion, then field coil protection is improved, but the assembly process becomes complex and difficult to automate
Solution Approach 1:
The patent merges the field coil assembly with the rotor insulator by providing guide pockets directly on the rotor insulator body. The field coils are assembled into these guide pockets along with lead wires and twisted parts, eliminating the need for separate insulator tube assembly. This integration reduces process complexity while maintaining corrosion protection through the epoxy coating that fills the guide pockets.
Solution Approach 2:
The patent extracts the insulator tube component and replaces it with guide pockets formed directly on the rotor insulator. This extraction simplifies the overall structure by removing an intermediate component while achieving the same protective function through the integrated guide pocket design and epoxy coating system.
3Ease of manufacture
If field coils are exposed outside the rotor assembly, then assembly is simplified, but corrosion occurs due to exposure
Solution Approach 1:
The patent changes the physical state of the guide pocket interior by filling it with epoxy coating material. This parameter change transforms the guide pocket from an open, exposed structure to a sealed, protected environment. The epoxy coating provides corrosion resistance to the field coils while maintaining the simplified assembly structure with integrated guide pockets.
4Manufacturing precision
If multiple processes (welding, soldering, bending, epoxy coating) are performed on twisted parts in guide pockets, then connection quality is improved, but process time increases
Solution Approach 1:
The patent applies preliminary action by pre-forming the twisted parts between lead wires and field coils before placing them in the guide pockets. This preliminary preparation allows subsequent welding, soldering, bending, and epoxy coating processes to be performed more efficiently in sequence, improving connection precision while reducing overall process time by avoiding repositioning and realignment.
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 solution securely fastens field coils and lead wires, prevents corrosion, and simplifies the assembly process, reducing defects and costs while enhancing durability and resistance to vibration at high speeds.
Implementation Method 1
epoxy is coated on the twisted parts and the guide pockets, and curing is performed
Data Source
AI summary
A connection structure and a connection method of connecting field coils and lead wires in a vehicle alternator. The connection structure includes a rotor assembly, a rear fan, and a rotor insulator. The rotor assembly includes a rotor shaft, a spool bobbin, and rotor segments. In the connection structure, a soldering or welding process is performed on twisted parts, which are formed by twisting field coils and lead wires around each other, the twisted parts are bent in the guide pockets of the rotor insulator, epoxy is applied to the outer surfaces of the twisted parts and the inner surfaces of guide pockets, and the rear fan is coupled to the front of the rotor insulator so that the inner surfaces of the protrusion hubs of the rear fan are in close contact with the guide pockets of the rotor insulator.