Rotating Machine Armature Wedge Radial Insertion
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Solution Overview
Problem
Conventional wedges in rotating electric machines are inefficient to assemble, lack durability, and increase manufacturing costs due to their complex configuration and axial insertion, which can lead to interference with coils and require excessive force during assembly.
Innovation Solution
The use of metal plates with elasticity and a V-shaped cross-section for the wedges, allowing radial insertion and improved assembly efficiency, with insulating coatings to prevent electrical interference, and coupling ends that secure the wedges to the core, enhancing durability and assembly ease.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If plastic material is used for the wedge, then the wedge can be easily inserted into the slot, but the wedge lacks stiffness and durability
Solution Approach 1:
The wedge is made of a composite structure combining a resin material (for ease of insertion and damping) and a reinforcement member (for stiffness and durability). The reinforcement member, made of rigid material such as metal or fiber-reinforced plastic, is embedded within the resin material to provide the necessary mechanical strength while the resin material facilitates easy insertion and provides damping characteristics.
2Ease of manufacture
If the wedge is inserted in the axial direction through openings, then the wedge can be assembled after coils are wound, but the assembly efficiency decreases and the process becomes complex
Solution Approach 1:
Instead of inserting the wedge in the axial direction through openings after coil winding, the invention inverts the insertion direction to insert the wedge from the radial direction through the slot opening. This allows the wedge to be inserted before or during coil winding operations, simplifying the assembly process and improving efficiency by eliminating the need for separate post-winding wedge installation steps.
3Ease of operation
If the wedge is inserted in the axial direction, then the wedge can be assembled, but great power is required and the wedge may get caught on the coils
Solution Approach 1:
The invention inverts the insertion direction from axial to radial. By inserting the wedge from the radial direction through the slot opening rather than pushing axially through the entire slot length, the required insertion force is significantly reduced and the risk of the wedge getting caught on protruding coils is eliminated.
Solution Approach 2:
The wedge is designed with a tapered shape that allows it to be preliminarily inserted into the slot opening from the radial direction before the coils are fully positioned. This preliminary action enables the wedge to be seated in place without requiring forceful axial insertion that could cause it to catch on coils.
4Ease of manufacture
If a simple plastic wedge structure is used, then the wedge fabrication is easy, but the wedge lacks durability and may be difficult to assemble
Solution Approach 1:
The wedge employs a composite structure where a resin material provides ease of fabrication and molding, while an embedded reinforcement member made of rigid material (metal or fiber-reinforced plastic) provides the necessary durability and assembly reliability. This composite approach maintains manufacturing simplicity while significantly improving mechanical properties.
Solution Approach 2:
The wedge incorporates a tapered (curved) shape rather than a straight cylindrical form. This curved geometry facilitates easier radial insertion by reducing resistance during insertion and improving assembly reliability, while still being manufacturable using standard molding techniques for the resin portion.
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 new wedge design improves assembly efficiency and durability by allowing radial insertion, reducing interference with coils and increasing stiffness, thus simplifying the assembly process and reducing manufacturing costs.
Implementation Method 1
both sides are able to spread outward when the elastic body is closed with a bent point of the substantially V shape as the substantial center
Implementation Method 2
The surfaces of the main plate, or one surface of the main plate that contacts (e.g., is disposed adjacent to) the coils within the slot may be coated with an insulating material, or an insulating layer may be interposed between the surface of the main plate and the coils to insulate the surface of the main plate from the coils
Data Source
Figure 1
Figure 2
AI summary
The present disclosure provides an armature of a rotating electric machine. The armature of the rotating electric machine includes a wedge that is configured to close an opening of a slot around which coils are wound and support the coils disposed to a left side and a right side of the slot to prevent the coils from seceding from a core. The wedge includes a main plate that has a substantially V-shaped section. In addition, a support plate of the wedge is coupled with the main plate within the main plate and is configured to support the main plate in directions in which the main plate spreads to maintain a shape of the main plate.