Connection Ring Lug Geometry for Gap-Free Stator Conductor Welding
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Solution Overview
Problem
Conventional electric machines face issues with fitting gaps at the connection between the connection ring assembly and conductor elements, which can negatively impact the weld quality due to the clamping jaw structure and non-ideal wire alignment.
Innovation Solution
A geometric configuration is introduced for the connection lug with a clamping portion of a smaller width and a fitting portion of a larger width, allowing the conductor to be spread and ensuring gap-free contact, achieved through a clamping tool that engages the connection lug, thereby eliminating or minimizing fitting gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a straight connection lug with parallel edges is used for clamping the conductor element, then the clamping structure is simple, but a fitting gap is produced at the joint which deteriorates weld quality
Solution Approach 1:
The connection lug is divided into two distinct functional portions: a clamping portion with a first width for engaging the conductor element, and a fitting portion with a second width for achieving gap-free contact. This segmentation allows each portion to be optimized for its specific function, resolving the contradiction between structural simplicity and fitting precision.
Solution Approach 2:
Different portions of the connection lug are given different width dimensions to serve different purposes. The clamping portion has a smaller first width suitable for conductor engagement, while the fitting portion has a larger second width to eliminate fitting gaps. This local differentiation of geometric properties directly addresses the technical contradiction.
2Ease of manufacture
If the conductor element is clamped to a straight connection lug, then the clamping process is simple, but the non-ideal wire alignment produces a fitting gap that negatively impacts weld quality
Solution Approach 1:
The connection lug is pre-formed with a geometric configuration that includes both the clamping portion and the wider fitting portion. This preliminary geometric preparation ensures that when the conductor element is clamped, it is automatically positioned to achieve gap-free contact in the fitting portion, thereby improving weld quality without complicating the clamping process.
3Manufacturing precision
If a connection lug with a widening geometry is used to spread the conductor element, then a gap-free contact is achieved, but the connection lug structure becomes more complex
Solution Approach 1:
The connection lug incorporates a dynamic geometric transition from the narrower clamping portion to the wider fitting portion. This gradual widening allows the conductor element to be naturally spread and conform to the lug geometry during the clamping process, achieving gap-free contact while maintaining manufacturing feasibility.
Data Source
AI summary
An electric machine with a stator which includes a stator winding system and a connection ring assembly. The connection ring assembly has at least one connection lug for connecting a conductor end section of a conductor element of the stator winding system, and the conductor end section contacts the connection lug. The connection lug has a clamping portion for establishing the contact with the conductor end section, and a fitting portion for producing a fitted connection between the connection lug and the conductor end section. The connection lug has a first width along the circumference of the connection ring assembly in the clamping portion, and a second width along the circumference of the connection ring assembly in the fitted portion, and the first width is smaller than the second width.