Coil Wire Solder Joint Structure for Easier Motor End Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for connecting rectangular conducting wires in rotating electric machines, such as TIG welding, are complex and inefficient.
Innovation Solution
A coil wire module with hardened solder joints that facilitate the connection of coil wires by inserting their ends into a solder hardening space, where the solder melts and hardens to join the ends together, using a solder-incorporated solder jointing part with recessed portions and a cap/holder configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If TIG welding is used to connect rectangular conducting wires to busbars, then reliable electrical connection is achieved, but the connection process becomes complex and time-consuming
Solution Approach 1:
The patent replaces the TIG welding process (thermal/mechanical system) with a mechanical insertion system where coil wire ends are inserted into recesses of the busbar. The connection is secured through mechanical means (recess geometry, interference fit) rather than through welding, thereby eliminating the complexity of welding operations while maintaining reliable electrical connection.
Solution Approach 2:
The busbar is segmented with multiple recesses positioned at specific locations to accommodate individual coil wire ends. This segmentation allows each wire end to be independently inserted and connected, simplifying the overall connection process by breaking down the complex welding task into simple, repeatable insertion operations.
2Strength
If TIG welding is used to join busbars and rectangular conducting wires, then strong mechanical and electrical connection is achieved, but the task becomes complex and inefficient
Solution Approach 1:
The patent substitutes the TIG welding process with a mechanical insertion system. Coil wire ends are inserted into precisely formed recesses in the busbar, creating a secure mechanical connection through geometric interlocking and interference fit. This mechanical approach eliminates the time-consuming welding process while maintaining strong connection strength through optimized recess geometry and material properties.
Solution Approach 2:
The recesses are pre-formed in the busbar during manufacturing, preparing the connection interface in advance. This preliminary action eliminates the need for on-site welding operations, as the mechanical connection structure is already prepared and ready to receive the coil wire ends, thereby significantly improving connection efficiency and productivity.
3Ease of manufacture
If coil wire connection ends are inserted into solder hardening space with solder, then connection process is simplified, but alignment precision requirements increase
Solution Approach 1:
The solder is localized within the recess of the busbar, creating a localized bonding zone. The recess geometry provides local structural support and positioning features that guide the coil wire end into proper alignment. This localized approach to soldering reduces the overall alignment precision requirements compared to full-surface soldering, as the critical positioning is provided by the recess structure rather than requiring high-precision alignment over a large area.
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 solution simplifies and stabilizes the connection process, ensuring reliable and efficient joining of coil wires, even with imperfect alignment, while maintaining electrical and mechanical integrity.
Implementation Method 1
a solder melting inside a solder hardening space
Implementation Method 2
the solder melts inside a solder hardening space, in a state where at least two of the connection ends of the plurality of coil wires are inserted into the solder hardening space, and hardening to join the at least two of the connection ends together
Data Source
AI summary
A coil wire module for a rotating electric machine, the core wire module including: a plurality of coil wires that are configured to be provided in a core of the rotating electric machine; and a hardened solder, wherein: the plurality of coil wires each have a connection end that is configured to be exposed from an end of the core, and the hardened solder is formed by a solder melting inside a solder hardening space, in a state where at least two of the connection ends of the plurality of coil wires are inserted into the solder hardening space, and hardening to join the at least two of the connection ends together.