Claw Rotor End Wire Clip for Vibration Damping
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Solution Overview
Problem
The end wires of the excitation winding in rotary electrical machines with claw rotors are prone to premature breakage due to substantial vibrations during operation.
Innovation Solution
A securing clip is integrated into the claw rotor design, which includes crimping means and support features to be placed in a radial cavity between the fan and the magnet wheel, clamping the end wire to reduce vibrations and prevent breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the end wire is bent and passes through the radial cavity without additional securing means, then the device complexity is reduced, but the reliability deteriorates due to premature breakage from vibrations
Solution Approach 1:
The crimping means are pre-formed as integral parts of the clip, ready to perform the crimping action as soon as the clip is installed in the radial cavity. This preliminary preparation of the crimping structure eliminates the need for separate crimping tools or operations, while ensuring the end wire is securely fixed against vibrations from the outset
Solution Approach 2:
The clip acts as an intermediary component between the end wire and the radial cavity structure. It provides the crimping means that directly contact and secure the end wire, while the support means interface with the radial cavity wall, thereby mediating the mechanical connection and protecting the end wire from vibration-induced breakage
2Reliability
If the end wire is secured with a clip comprising crimping means, then the reliability is improved by reducing vibrations, but the device complexity increases
Solution Approach 1:
The clip combines multiple functions into a single integrated component: it provides structural support through the support means, secures the end wire through crimping means, and positions itself within the radial cavity. This merging of functions reduces the total number of separate components needed, thereby limiting the increase in device complexity while achieving reliable end wire fixation
Solution Approach 2:
The clip is designed as a multi-functional element that simultaneously performs support, crimping, and positioning functions. The single clip structure serves multiple purposes in securing the end wire against vibrations, making the solution efficient without requiring multiple separate components
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 securing clip effectively limits end wire vibrations, thereby reducing the risk of breakage and enhancing the durability of the electrical machine.
Implementation Method 1
crimping means which are designed to be disposed in the radial cavity, in order to crimp the part of the end wire of the winding which extends in the said radial cavity
Data Source
AI summary
A claw pole rotor comprises a shaft, first and second polar wheels fastened to the shaft, a winding provided with a winding insulator and surrounded by the first and second polar wheels, a commutator provided with at least one commutator ring, a fan fastened to the first polar wheel and disposed between the winding and the at least one commutator ring, at least one end-of-winding wire being linked to one of the at least one commutator rings, passing through a radial cavity provided between the fan and the first polar wheel. The winding insulator comprises a clip retaining the one end-of-winding wire. The retaining clip is fastened to the winding insulator and comprising crimping means intended to be disposed in the radial cavity to crimp the part of the end-of-winding wire extending into the radial cavity.