Armature Winding Weld Structure for Faster Thick-Wire Joining

Solution Overview

Problem

The increasing thickness of armature windings in rotating electrical machines due to higher output power requirements leads to longer welding times, thereby increasing manufacturing costs.

Innovation Solution

A rotating electrical machine wiring component with a wire shape, featuring a weld portion at one longitudinal end that extends along the alignment direction of the armature winding ends and includes protrusions that protrude along the winding ends, allowing for efficient welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If thicker armature windings are used to increase output power, then the power output is improved, but the welding time increases due to heat diffusion

Engineering Contradiction:

Improveoutput powerVSAvoidwelding time

Core Design Contradiction:

PowerVSLoss of time

Solution Approach 1:

The weld portion is divided into multiple protrusions that are distributed along the alignment direction. Each protrusion makes contact with a corresponding armature winding end, segmenting the welding process into multiple localized contact points. This segmentation prevents heat diffusion across the entire welding surface and concentrates heat at each protrusion contact point, thereby reducing overall welding time while maintaining the ability to handle thicker windings for higher output power

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The protrusions create localized welding zones with concentrated heat input at specific contact points along the armature winding ends. By concentrating the welding heat locally at each protrusion rather than distributing it across a large surface area, the welding process becomes faster and more efficient, resolving the contradiction between handling thicker windings (higher power) and reducing welding time

Inventive Principle:

Principle #3Local quality

2Reliability

If conventional welding methods are used on thick armature windings, then reliable connections are achieved, but manufacturing costs increase due to longer welding processes

Engineering Contradiction:

Improveconnection reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The weld portion is divided into multiple protrusions that are distributed along the alignment direction. Each protrusion makes contact with a corresponding armature winding end, segmenting the welding process into multiple localized contact points. This segmentation prevents heat diffusion across the entire welding surface and concentrates heat at each protrusion contact point, thereby reducing overall welding time while maintaining the ability to handle thicker windings for higher output power

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The protrusions create localized welding zones with concentrated heat input at specific contact points along the armature winding ends. By concentrating the welding heat locally at each protrusion rather than distributing it across a large surface area, the welding process becomes faster and more efficient, resolving the contradiction between handling thicker windings (higher power) and reducing welding time

Inventive Principle:

Principle #3Local quality

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 solution enables quick welding of thick armature windings, reducing manufacturing costs and improving efficiency by concentrating heat on the protrusions during the welding process.

Implementation Method 1

a weld portion that is provided at one longitudinal end and is connected to the plurality of ends of the armature winding by welding

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

the protrusions are melted and fused respectively with the plurality of ends of the armature winding

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS20250030294A1Rotating electrical machine wiring component, rotating electrical machine wiring component-connection structure, and rotating electrical machine assembly manufacturing method

Publication Date: 2025.01.23 PROTERIAL LTD

AI summary

A rotating electrical machine wiring component has a wire shape and is configured to be connected to a plurality of ends of an armature winding aligned in parallel in a predetermined alignment direction. The rotating electrical machine wiring component includes a weld portion that is provided at one longitudinal end and is connected to the plurality of ends of the armature winding by welding, wherein the weld portion extends in an extending direction along the alignment direction, and wherein the weld portion comprises protrusions that protrude respectively along the plurality of ends of the armature winding.