Aluminum Wound Wire Rotary Machine Corrosion Control
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Solution Overview
Problem
Rotary electric machines using aluminum wound wires face challenges in maintaining good electrical continuity while controlling costs, particularly when aluminum is used as the primary metal component, and existing solutions often require additional sealing materials to prevent corrosion at join sites.
Innovation Solution
A rotary electric machine design that incorporates a circuit terminal made from a conductive metal other than aluminum, with a wound wire terminal portion directly joined to the circuit terminal or via a coupling member also made from aluminum, ensuring electrical continuity and corrosion suppression without the need for additional sealing materials, and a manufacturing method that integrates the coupling member with the cover for enhanced water resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If aluminum wound wire is used to reduce weight and cost, then weight and manufacturing cost decrease, but electrical continuity and corrosion resistance at join sites deteriorate
Solution Approach 1:
A coupling member made of aluminum is introduced as an intermediary between the aluminum wound wire terminal portion and the copper circuit terminal. This coupling member facilitates reliable electrical connection while maintaining the weight reduction benefits of aluminum wiring. The coupling member is joined to the circuit terminal via welding, ensuring good electrical continuity despite the aluminum-copper interface.
Solution Approach 2:
Tin plating is applied to the circuit terminal at the join site where it connects to the aluminum coupling member. This parameter change in surface composition prevents corrosion at the aluminum-copper interface by creating a protective barrier, thereby maintaining electrical continuity and reliability while using aluminum wound wire.
2Ease of manufacture
If aluminum wound wire is used to reduce cost, then manufacturing cost decreases, but additional sealing materials are required to prevent corrosion, increasing device complexity
Solution Approach 1:
The coupling member serves as an intermediary that inherently provides corrosion resistance at the join site through its aluminum composition and tin-plated interface. This eliminates the need for additional sealing materials or protective coatings, reducing device complexity while maintaining cost-effectiveness.
Solution Approach 2:
The coupling member and circuit terminal interface is designed to be self-protecting against corrosion through the tin plating on the copper terminal. This self-service approach prevents corrosion without requiring external sealing materials, thereby reducing device complexity and manufacturing steps.
3Reliability
If circuit terminal is made from copper for good electrical conductivity, then electrical continuity improves, but cost increases due to joining dissimilar metals
Solution Approach 1:
Tin plating is applied to the copper circuit terminal at the join site, changing the surface parameters to prevent corrosion. This allows reliable joining of dissimilar metals (aluminum coupling member to copper terminal) while maintaining good electrical conductivity through the copper material.
Solution Approach 2:
The tin-plated surface acts as an intermediary layer between the aluminum coupling member and copper circuit terminal, facilitating reliable electrical connection while preventing galvanic corrosion. This maintains electrical conductivity benefits of copper while enabling cost-effective aluminum wiring.
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 enables reliable electrical continuity between the circuit terminal and wound wire while preventing corrosion and reducing costs, with improved assembly efficiency and reduced assembly processes by minimizing the number of join locations and using tin plating for enhanced corrosion protection.
Implementation Method 1
The circuit terminal is configured from a conductive metal other than aluminum... enables good electrical continuity between the wound wire and the circuit terminal
Implementation Method 2
with improved assembly efficiency and reduced assembly processes by minimizing the number of join locations and using tin plating for enhanced corrosion protection
Data Source
AI summary
In a rotary electric machine, wound wires are connected to a first terminal and a second terminal. Circuit terminals that are configured from a conductive metal other than aluminum, and the first terminal and the second terminal that are configured from a metal with a principal component of aluminum are joined together inside a circuit chamber that has high water resistant properties. Corrosion is accordingly suppressed at join sites of the circuit terminals with the first terminal and the second terminal. There is therefore no need to coat the join sites with for example a sealing material in order to suppress corrosion at the join sites. Good electrical continuity is accordingly enabled between the circuit terminals and the wound wires while suppressing an increase in costs, even when the wound wire is configured from a metal with a principal component of aluminum.