Conductor Bar Fabrication with Rounded Edge Moulding
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Solution Overview
Problem
The fabrication of conductor bars for electric machines results in uneven surfaces due to strand transposition, leading to excessive losses, heating, and reduced lifespan, with existing methods requiring manual polishing and putty application causing sharp edges and undefined electrical fields.
Innovation Solution
A method involving a mica tape with putty and a pressing mould with rounded edges to apply and harden the putty on conductor bars, eliminating the need for manual polishing and ensuring defined radii, thereby enhancing electrical field homogeneity and extending the lifespan of the conductor bars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If putty is applied to the conductor bar surface using rectangular steel rods, then the surface can be filled, but sharp edges are created leading to undefined electrical field strengths
Solution Approach 1:
The patent applies putty with rounded edges instead of sharp rectangular edges. The rounded shape eliminates stress concentration points and creates defined radii that prevent undefined electrical field strengths, directly resolving the contradiction between surface filling and electrical field homogeneity.
2Manufacturing precision
If manual polishing is performed on the conductor bar edges, then edge definition can be improved, but the process is time-consuming and quality is inconsistent
Solution Approach 1:
The patent incorporates edge rounding directly into the putty application process itself, rather than requiring a separate subsequent polishing step. The putty is applied with rounded edges from the beginning, which eliminates the need for manual polishing and ensures consistent quality while maintaining productivity.
3Ease of manufacture
If the conductor bar has sharp edges after putty application, then fabrication is simpler, but additional polishing steps are required
Solution Approach 1:
The patent combines the putty application function with the edge rounding function into a single integrated process step. By using a putty application method that inherently creates rounded edges, the patent merges two previously separate operations (putty application and edge rounding/polishing) into one, reducing overall process complexity.
Data Source
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AI summary
The present disclosure relates to a method for fabrication of a conductor bar and to a use of a conductor tape with applied putty for the fabrication of a conductor bar. Described is a method for fabrication of a conductor bar with the following steps, applying a putty at one side of a conductor tape, applying a release foil at the other side of the putty opposed to the conductor tape, removing the release foil before applying the conductor tape to the narrow side of the conductor bar, providing a pressing mould with rounded edges at the inner side of the pressing mould, surrounding the conductor bar with putty and conductor tape with the pressing mould, and hot pressing the conductor bar with the pressing mould.