Rotary Electric Machine Armature Segment Conductor Joining
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Solution Overview
Problem
Existing techniques for joining segment conductors in rotary electric machine armatures face challenges in accurately positioning and securely connecting the conductors due to radial movement, leading to difficulties in forming a stable coil configuration.
Innovation Solution
A method involving a cylindrical armature core with axial slots and radially opening slots, where segment conductors with crossover portions and joint surfaces are arranged to face each other, with their movement regulated to prevent displacement during joining, using a pressing device to ensure precise alignment and secure bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If segment conductors are pressed from both sides in the axial direction to join them, then the joining force is improved, but the positioning accuracy deteriorates due to radial movement and displacement
Solution Approach 1:
The patent transitions from axial direction pressing to radial direction pressing. The pressing device presses the conductor side portions from the radially inner side toward the radially outer side, changing the pressing dimension from axial to radial. This dimensional change allows the joint portions to face each other accurately in the axial direction while being secured by radial pressing force, simultaneously achieving both positioning accuracy and joining force.
Solution Approach 2:
The patent introduces a pressing device as an intermediary tool that applies radial pressing force to the conductor side portions. This intermediary mechanism enables precise control of the pressing process, positioning the joint portions accurately before applying joining force, thereby resolving the contradiction between positioning accuracy and joining strength.
2Manufacturing precision
If segment conductors are arranged with facing joint portions for joining, then the positioning is improved, but the stability deteriorates due to radial movement during the joining process
Solution Approach 1:
The patent stabilizes the conductor side portions by applying pressing force in the radial direction rather than the axial direction. This radial pressing constrains the conductors against radial movement while maintaining the axial alignment of joint portions, simultaneously achieving positioning accuracy and stability during the joining process.
Solution Approach 2:
The pressing device performs preliminary positioning and stabilization of the conductor side portions in the radial direction before the actual joining process. By pre-constraining the conductors radially, the joint portions are accurately positioned and stabilized, preventing displacement during subsequent joining operations.
3Reliability
If pressing force is applied from both axial sides to join segment conductors, then the joining reliability is improved, but the complexity of the joining process increases due to difficulty in positioning
Solution Approach 1:
The patent simplifies the joining process by changing the pressing direction from axial to radial. A single radial pressing operation from the radially inner side toward the radially outer side simultaneously achieves both positioning and joining, eliminating the need for complex coordinated axial pressing from both sides while maintaining joining reliability.
Solution Approach 2:
The pressing device serves as an intermediary that performs both positioning and joining functions through a single radial pressing action. This intermediary mechanism consolidates multiple steps (positioning + joining) into one operation, reducing process complexity while ensuring reliable joining through controlled radial pressing force.
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 allows for stable and efficient joining of segment conductors, reducing the risk of displacement and separation during the joining process, thereby facilitating the formation of a well-structured coil that enhances the performance of the rotary electric machine.
Implementation Method 1
pressing, in a radial direction, the conductor side portions of the plurality of segment conductors disposed in the slot
Data Source
AI summary
A method of manufacturing a rotary electric machine armature that includes a cylindrical armature core in which a plurality of slots that extend in an axial direction are disposed in a circumferential direction and a coil wound around the armature core, the slots having respective radial openings that open in a radial direction, and the coil being formed by joining a plurality of segment conductors to each other.