Armature Segment Conductor Assembly Without Welding Tool Space

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Solution Overview

Problem

The existing method of manufacturing a stator requires a tool space for joining the connection end portions of the coil and power lines, leading to an increase in the size of the armature due to the need to position members around the connection end portions for welding, which complicates the manufacturing process.

Innovation Solution

A method where segment conductors with pre-connected end portions and power terminal members are disposed in the armature core, allowing for electrical connections without the need for a tool space, enabling closer proximity of other components and reducing the armature's size by joining the leg portions of the conductors within the core.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If connection end portions of the coil and power lines are joined after inserting conductor segments into the stator core, then electrical connections can be established, but a tool space is required around the connection end portions which increases the size of the armature

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidarmature size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The connection end portions of the conductor segments are electrically connected to each other before inserting the conductor segments into the stator core. This preliminary connection action eliminates the need for tool space around the connection portions during assembly, thereby preventing an increase in armature size while ensuring reliable electrical connections.

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If members are disposed around the connection end portions for welding, then joining work can be performed, but the stator size increases due to the required tool space

Engineering Contradiction:

Improvejoining work feasibilityVSAvoidstator size

Core Design Contradiction:

Ease of manufactureVSVolume of moving object

Solution Approach 1:

The electrical connections between connection end portions are established before inserting the conductor segments into the stator core. This preliminary action eliminates the need for subsequent joining work within the stator assembly, removing the requirement for tool space and preventing an increase in stator size.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The joining work is extracted from the stator assembly process and performed externally before insertion. By taking out the connection operation from the final assembly stage, the patent eliminates the need for tool space within the stator, thereby maintaining compact dimensions.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If connection end portions are joined after insertion, then electrical connections can be made, but the manufacturing process becomes more complex due to tool space requirements

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The connection end portions are electrically connected before inserting the conductor segments into the stator core. This preliminary action simplifies the manufacturing process by eliminating the need for complex tooling and positioning arrangements during assembly, while still ensuring reliable electrical connections.

Inventive Principle:

Principle #10Preliminary action

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

This approach prevents the increase in size of the armature by eliminating the need for a tool space, allowing for more compact designs and simplified manufacturing by pre-forming electrical connections within the core, thus enhancing manufacturing efficiency.

Implementation Method 1

the distal end portion of the first-side conductor segment and the distal end portion of the second-side conductor segment are joined to each other by heating the first-side conductor segment and the second-side conductor segment while being pressed against each other from both sides in the axial direction

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS12057744B2Method of manufacturing armature

Publication Date: 2024.08.06 AISIN CORP

AI summary

A method of manufacturing an armature includes: a step of preparing first segment conductors in which a plurality of end portions, or an end portion and a power terminal member, are electrically connected to each other; a step of disposing leg portions of the first segment conductors and leg portions of second segment conductors in an armature core; and a step of joining the leg portions of the first segment conductors and the leg portions of the second segment conductors to each other.