Connecting Ring with Open Grooves for Stator Coil Assembly
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Solution Overview
Problem
The manufacturing and assembly of power distribution apparatus for rotary electric machines, such as electric motors or generators, are complex and time-consuming due to the need for precise alignment and embedding of wire ends into connecting rings, requiring multiple assembly steps and machining operations.
Innovation Solution
The use of connecting rings with open grooves allows for quick and accurate electrical connections by inserting wire ends without full embedding, and a mounting ring with aligned holes facilitates a single-step assembly, reducing the number of assembly steps and machining requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire ends are fully embedded into connecting rings through multiple assembly steps and machining operations, then reliable electrical connections are achieved, but manufacturing complexity and assembly time increase significantly
Solution Approach 1:
The connecting ring is segmented with multiple open grooves that receive wire ends, allowing individual wire connections without requiring complete embedding of all wires. This segmentation enables selective connection while maintaining reliability, reducing assembly complexity from multiple steps to a single insertion operation.
Solution Approach 2:
Instead of requiring full embedding of wire ends into the connecting ring (excessive action), the invention uses partial action by creating open grooves that accept wire ends for connection without complete embedding. This partial connection approach achieves sufficient electrical reliability while dramatically simplifying the assembly process.
2Manufacturing precision
If multiple assembly steps and machining operations are used for precise alignment and embedding of wire ends, then secure electrical connections are formed, but assembly time and manufacturing cost increase
Solution Approach 1:
The open grooves are pre-formed in the connecting ring during manufacturing, establishing precise alignment features before assembly. This preliminary action eliminates the need for time-consuming alignment and embedding operations during assembly, maintaining manufacturing precision while reducing assembly time significantly.
Solution Approach 2:
The invention extracts the time-consuming embedding operation from the assembly process by using open grooves that accept wire ends directly. The precise alignment function is extracted and built into the groove structure itself, allowing quick insertion without subsequent embedding steps, thus reducing assembly time while maintaining precision.
3Reliability
If traditional embedding methods are used for connecting wire ends to connecting rings, then reliable power distribution is achieved, but the number of assembly steps and machining operations increases
Solution Approach 1:
The open grooves in the connecting ring provide self-aligning features that guide wire ends into proper positions during insertion. This self-service mechanism ensures reliable power distribution connections without requiring external alignment tools or multiple adjustment steps, thereby improving assembly productivity while maintaining connection reliability.
Data Source
AI summary
In some examples, at least one connecting ring may connect a plurality of stator coils of the same phase. For instance, the at least one connecting ring may include at least one linear conductor formed in a ring-like shape. The linear conductor may include a plurality of terminal sections, each terminal section including an open groove extending perpendicular to a plane formed by the ring-like shape. The open grooves may be positioned around a circumference of the connecting ring for receiving respective wire ends of respective stator coils inserted into the open grooves for forming an electrical connection between the respective wire ends and the connecting ring at the respective terminal sections.