Rotary Armature Segment Conductor Joining via Positioning Mediator
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Solution Overview
Problem
Existing methods for joining segment conductors in rotary electric machine armatures face challenges in accurately positioning and securely connecting the conductors due to axial pressure, leading to difficulties in forming a stable coil configuration.
Innovation Solution
A method involving a cylindrical armature core with radially opening slots, where segment conductors are arranged with facing joint surfaces to facilitate precise alignment and regulation of movement, allowing for axial pressing to join the conductors while maintaining radial stability, ensuring proper alignment and secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If segment conductors are pressed from both sides in the axial direction, then joining of conductors is achieved, but positioning accuracy deteriorates making it difficult to appropriately join the conductors
Solution Approach 1:
A positioning member is introduced as an intermediary element between the segment conductors and the pressing mechanism. This positioning member has a positioning protrusion that fits into a positioning groove on the conductor side portion, providing a reference for accurate positioning during the pressing operation. The positioning member mediates between the need for axial pressing force and the requirement for precise radial positioning, allowing the conductors to be accurately positioned while being pressed from both sides in the axial direction.
2Strength
If axial pressing force is applied to join segment conductors, then connection strength is improved, but radial displacement control becomes difficult
Solution Approach 1:
The positioning member serves as a mediator that decouples the axial pressing function from the radial positioning function. The positioning protrusion and groove provide radial positioning stability independently of the axial pressing force, allowing strong axial connection while maintaining stable radial positions of the segment conductors throughout the joining process.
3Ease of manufacture
If segment conductors are arranged in slots without positioning regulation, then ease of assembly is improved, but joining accuracy deteriorates
Solution Approach 1:
The positioning member is designed to be simple in structure, consisting of a positioning protrusion and corresponding groove, which can be easily integrated into the existing slot arrangement. This positioning mechanism provides accurate joining reference without significantly complicating the assembly process, as the positioning features guide the segment conductors into correct positions during assembly.
Solution Approach 2:
The positioning mechanism uses asymmetric features (protrusion and groove) that provide unidirectional positioning control. The groove is shaped to receive the protrusion in a specific orientation, ensuring accurate positioning of the segment conductors in the radial direction while maintaining simplicity of the overall assembly process.
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 enables easy and accurate joining of segment conductors, restricting radial displacement and ensuring stable coil formation, thereby improving the manufacturing process of rotary electric machine armatures.
Implementation Method 1
joining the joint portion of the first segment conductor and the joint portion of the second segment conductor to each other by pressing at least one of the first segment conductor and the second segment conductor in the axial direction such that the first segment conductor and the second segment conductor approach each other while maintaining a regulating state
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.