Coil End Connecting Structure Using Segmented Flat Wire Insertion
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Solution Overview
Problem
The existing method of deforming the end of a flat wire into a V-shape and inserting it into a sleeve to connect a coil winding is limited by the size of the sleeve, requiring a larger diameter sleeve than necessary, which increases the cross-sectional area requirement, necessitating additional conductor portions to secure the connection, leading to increased costs and labor.
Innovation Solution
A coil end connecting structure that forms a narrow-width part by cutting the coil end on one side, allowing it to be inserted into a smaller diameter sleeve with a crimp part for electrical connection, eliminating the need for additional conductor portions by increasing the aspect ratio of the conductor portion within the sleeve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the end of the flat wire is deformed into a V-shape and inserted into a small diameter sleeve, then the current carrying capacity is improved, but the manufacturing difficulty increases due to bending limitations
Solution Approach 1:
The flat wire end is divided into two separate conductor portions by cutting, rather than bending into a V-shape. This segmentation allows the conductors to be inserted into the sleeve without bending, eliminating the manufacturing difficulty while maintaining the current carrying capacity through proper arrangement of the cut portions.
2Ease of manufacture
If a larger diameter sleeve is used to accommodate the V-shaped end, then the ease of manufacture is improved, but the cross-sectional area requirement increases necessitating additional conductor portions
Solution Approach 1:
By cutting the flat wire end into segments and inserting them directly into the sleeve without bending, a smaller diameter sleeve can be used that satisfies both the ease of manufacture and the current carrying capacity requirements, eliminating the need for additional conductor portions.
Solution Approach 2:
Instead of solving the insertion problem by increasing sleeve diameter (one dimension), the invention changes the approach by cutting the conductor and arranging segments within the same sleeve diameter, effectively using a different dimensional strategy to achieve both ease of manufacture and current capacity.
3Quantity of substance
If additional conductor portions are inserted to secure the cross-sectional area, then the current carrying capacity is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The invention uses segmentation of the single flat wire end into cut portions that are arranged within the sleeve to provide sufficient cross-sectional area, eliminating the need for additional separate conductor portions and reducing device complexity.
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 a necessary and sufficient connection without increasing the size of the end connecting member, reducing costs and labor by using a smaller diameter sleeve and eliminating the need for additional conductor portions.
Implementation Method 1
a crimp part which crimps the cylinder body part to electrically connect the narrow-width part and the end connecting member
Data Source
AI summary
A coil end connecting structure for connecting a coil end part extending from a coil winding part formed by winding a flat wire, includes: a narrow-width part which is formed by forming a cut part made by cutting out the coil end part on a tip side at least on one side in a width direction thereof; an end connecting member which includes a cylinder body part in a cylindrical shape and in which the narrow-width part is inserted in an inner cylinder part of the cylinder body part; and a crimp part which crimps the cylinder body part to electrically connect the narrow-width part and the end connecting member.