Segment Conductor Armature Joints With Chamfered Edge Overlap
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Solution Overview
Problem
The existing armature designs, such as those described in JP 2006-141076 A, suffer from a shortage of joint area due to the small overlapping areas of chamfered facing surfaces of conductor segments, which can hinder effective joint formation.
Innovation Solution
The armature design includes overlapping facing surfaces of segment conductors as viewed in the radial direction, with chamfered parts only on the circumferential sides of the end parts, ensuring a sufficient joint area is maintained even with chamfered edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional armature designs with separate pole pieces and coils are used, then the motor can achieve basic rotational motion, but the device complexity and manufacturing difficulty increase significantly
Solution Approach 1:
The patent combines the pole piece and coil into a single integrated armature component where the coil is formed as an integral part of the armature body. This merging eliminates the need for separate assembly of pole pieces and coils, reducing device complexity while maintaining motor performance through the unified magnetic circuit design.
Solution Approach 2:
The armature design integrates multiple functions into a single component: the armature body serves as both the structural support and the magnetic pole piece, while the integrated coil provides both the electromagnetic winding and the magnetic flux path. This multi-functionality reduces the number of parts without compromising motor reliability.
2Productivity
If traditional winding methods with multiple separate coils are used, then the motor can generate sufficient torque, but the manufacturing precision requirements and production time increase
Solution Approach 1:
The patent segments the coil into discrete turns that are individually formed and then assembled into the complete coil structure. This segmentation allows each turn to be manufactured with standard precision using automated winding machines, eliminating the need for high-precision continuous winding while maintaining the required magnetic field distribution and torque output.
3Device complexity
If separate pole pieces with insulation layers are used, then magnetic flux can be directed properly, but the number of components and assembly steps increase
Solution Approach 1:
The pole piece and insulation layer are merged into a single integrated structure where the insulation is formed as an integral part of the pole piece geometry. This eliminates separate insulation components and assembly steps while maintaining proper magnetic flux direction through the designed geometric features of the integrated component.
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 configuration prevents a shortage of joint area, enhancing the stability and effectiveness of the electrical connection between conductor segments.
Implementation Method 1
an armature (20) comprising a core (21) and a coil (22) wound around the core (21)
Implementation Method 2
a stator (10) comprising a yoke (11) and a permanent magnet (12) mounted on the yoke (11)... the coil (22) wound around the core (21)
Data Source
Figure 1
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Figure 3
AI summary
In this armature, facing surfaces which are portions where a first segment conductor and a second segment conductor are joined together are disposed so as to overlap each other as viewed in a radial direction, and an end part of at least one of the first segment conductor and the second segment conductor is provided with chamfered parts at edge parts on both circumferential sides of the end part.