Deformable Damper for Electrical Machine Interconnector Vibration

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Solution Overview

Problem

Electrical machines, particularly alternators in range-extender systems for electric vehicles, face damage to welding tongues on interconnectors due to vibratory stresses, which can lead to poor assembly and reduced machine performance.

Innovation Solution

Incorporating a deformable damper between the interconnector and the closure flange of the electrical machine to absorb vibratory stresses, limiting relative movements and protecting the welding tongues, with the damper being compressible and supported by radial ribs and studs for enhanced contact and retention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the machine uses a rigid assembly structure, then assembly precision is improved, but the welding tongues are damaged by vibratory stresses

Engineering Contradiction:

Improveassembly precisionVSAvoidwelding tongue integrity

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

A damper made of deformable material is introduced as an intermediary element between the interconnector and the closure flange. This damper absorbs vibratory stresses and prevents them from reaching the welding tongues, while still maintaining assembly precision through its deformable nature that allows controlled movement.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The damper is pre-installed between the interconnector and closure flange to provide beforehand cushioning against vibratory stresses. This protective measure is in place before the machine operates, preventing damage to the welding tongues from the outset.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If the machine allows relative movement between parts, then vibratory stress damage is reduced, but assembly stability deteriorates

Engineering Contradiction:

Improvewelding tongue protectionVSAvoidassembly stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The assembly structure transitions from a completely rigid configuration to a dynamic one where the damper can deform in response to vibratory stresses. This dynamic element allows controlled relative movement that protects the welding tongues while maintaining overall assembly stability through the damper's restraining features.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The damper is made of a deformable material that acts as a flexible element between rigid components. This flexible material allows the assembly to accommodate vibratory stresses through controlled deformation while maintaining structural integrity and assembly stability.

Inventive Principle:

Principle #30Flexible shells and thin films

3Object-affected harmful factors

If the damper is made fully deformable, then vibratory stress absorption is improved, but the damper cannot maintain positional stability

Engineering Contradiction:

Improvevibratory stress absorptionVSAvoiddamper positional stability

Core Design Contradiction:

Object-affected harmful factorsVSStability of the object's composition

Solution Approach 1:

The damper is segmented with multiple restraining features (first restraining feature engaging the interconnector and second restraining feature engaging the closure flange) that divide the damper's functionality into distinct zones: one for absorption of vibratory stresses and another for maintaining positional stability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the damper have different properties: the bulk material is deformable for absorbing vibratory stresses, while the restraining features provide localized structural support to maintain positional stability. This local differentiation of properties allows the damper to simultaneously absorb vibrations and maintain position.

Inventive Principle:

Principle #3Local quality

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 deformable damper effectively reduces damage to the welding tongues and improves assembly stability by minimizing relative movements during vibratory stresses, enhancing the durability and performance of the electrical machine.

Implementation Method 1

at least one damper (83) made of a deformable material which is designed to be fitted compressed between the interconnector (22) and the closure flange (74)

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS10020708B2Electrical machine with damper to resist vibratory stresses mechanically, and corresponding damper

Publication Date: 2018.07.10 VALEO EQUIP ELECTRIC MOTEUR

AI summary

An electrical rotating machine includes a stator (11) provided with teeth (14) around which a group of coils (19) is wound, an annular interconnector (22) resting on a stator lamination stack (11) provided with tongues (36) to which ends (191, 192) of the coils (19) are welded for the formation of phases (U, V, W) of the electrical machine, and a closure flange (74) for closing a housing (70) for receiving the stator (11). The machine also includes at least one damper (83) consisting of a deformable material, configured to be mounted so as to be compressed between the interconnector (22) and the closure flange (74) of the machine. The invention also relates to the corresponding damper.