Rotating Machine Electrical Distribution Member Axial Length Reduction
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Solution Overview
Problem
The existing wire connection structures for rotating electrical machines result in an increase in axial length and pose challenges in preventing coating layer melting during welding, as well as maintaining appropriate spatial distances between conductor sections and coil ends.
Innovation Solution
The electrical distribution member employs a configuration of electrical conducting wires with a conductive metal body and a removable coating layer, where the first wires extend axially and the second wires are bent radially to follow the circumferential direction, with the second wires' coating layer removed over a longer length than the first wires', allowing for efficient welding without coating layer melting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coil ends are extended axially to follow the bent tip portions of lead wires, then the connection between coil ends and lead wires is improved, but the axial length of the rotating electrical machine increases
Solution Approach 1:
The lead wire configuration transitions from a bent tip portion extending axially to a structure where the joining portion extends in the axial direction while the main body extends in the radial direction. This dimensional reorientation allows the lead wire to connect coil ends without increasing axial length, as the connection is achieved through radial extension followed by axial joining portion.
Solution Approach 2:
The lead wire is designed with different structural characteristics in different regions: the main body section extends radially with coating layer preserved for insulation, while the joining portion extends axially with coating layer removed for welding. This local differentiation enables both electrical insulation and reliable welding connection without compromising either function.
2Length of moving object
If the lead wire shape is altered to shorten axial length, then the axial length of the rotating electrical machine is reduced, but the coating layer may melt during welding due to heat
Solution Approach 1:
The coating layer is selectively removed only from the joining portion where welding occurs, while being preserved on the main body section for electrical insulation. This local differentiation ensures that heat during welding does not affect the coating layer on the insulated portions, preventing unwanted melting while enabling reliable welding at the joining portion.
Solution Approach 2:
The coating layer is removed in advance from the joining portion before the welding process. This preliminary action prepares the surface for welding by exposing the conductive metal, ensuring proper weld adhesion while preventing the coating layer from melting during the subsequent welding operation.
3Ease of manufacture
If the coating layer is removed from the lead wire, then welding to the coil end is facilitated, but electrical insulation is compromised
Solution Approach 1:
The lead wire structure incorporates spatial differentiation of the coating layer: removed from the joining portion to enable welding, and preserved on the main body section to provide electrical insulation. This local quality variation allows the same component to fulfill both welding accessibility and electrical insulation requirements simultaneously.
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
This configuration effectively suppresses axial length increase and prevents coating layer melting during welding, ensuring reliable connections while maintaining spatial integrity and electrical insulation.
Implementation Method 1
a plurality of electrical conducting wires each being made of a solid wire, to connect a plurality of coil ends and electrodes respectively, of a terminal block together
Implementation Method 2
a coating layer, which is being provided over a surface of that electrical conducting body, while being removed therefrom over a range of a predetermined length including a joining portion to be welded to the coil end
Implementation Method 3
a joining portion to be welded to the coil end
Data Source
AI summary
An electrical distribution member includes a plurality of electrical conducting wires made of a solid wire. The electrical conducting wires each include an electrical conducting body, and a coating layer provided over a surface of that electrical conducting body, while removed therefrom over a respective predetermined length including a joining portion. The electrical conducting wires include at least one first electrical conducting wire having a joining portion extending in an axial direction of a stator core, and at least one second electrical conducting wire having a joining portion bent in relation to a radial direction of the stator core in such a manner as to follow a circumferential direction of the stator core. The predetermined length of the second electrical conducting wire with the coating layer removed therefrom is longer than the predetermined length of the first electrical conducting wire with the coating layer removed therefrom.