Electrical Machine Circuit Element Rectangular Clips
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Solution Overview
Problem
Traditional electrical machine circuit elements, such as laminations in electric motors and transformers, suffer from deformations and reduced circularity of central holes due to clip securing, leading to increased costs and reduced efficiency, and are complex to manufacture with circular arc-shaped edges.
Innovation Solution
The electrical machine circuit element features rectangular plan clips and seats that do not interfere with the central hole's dimensions, allowing precise axial hole circularity and simplified die-casting of aluminum rings, eliminating the need for relief holes and reducing material loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If circular arc-shaped clips and seats are used to connect laminations, then the laminations can be locked together, but the central hole becomes deformed and less circular
Solution Approach 1:
The connection system is segmented into two distinct functional parts: rectangular clips for locking and circular arc-shaped seats for positioning. This segmentation allows each component to perform its specific function without interfering with the central hole's circularity, as the rectangular clips engage with the circular seats rather than directly deforming the hole area
Solution Approach 2:
Different geometric shapes are assigned to different locations: rectangular clips are used at connection points where locking strength is needed, while circular arc-shaped seats are positioned to maintain the central hole's circularity. This local differentiation resolves the conflict between connection strength and hole precision
2Ease of operation
If relief holes are provided in clips and seats, then the laminations can be rotated during assembly, but the lamination weight is reduced and efficiency worsens
Solution Approach 1:
The harmful relief holes are completely removed from the design. Instead, the rectangular clips are given sufficient inherent flexibility to accommodate the necessary rotation during assembly without requiring material removal. This extraction eliminates the weight loss and efficiency degradation caused by relief holes while maintaining the rotation capability
3Strength
If circular arc-shaped clips and seats are formed, then the laminations can be connected, but the manufacturing complexity increases
Solution Approach 1:
Instead of forming complex circular arc-shaped clips (which would be difficult), the patent inverts the approach: circular arc-shaped seats are formed in the laminations, and simple rectangular clips are used to engage with these seats. This inversion makes the manufacturing process much simpler while maintaining connection strength, as rectangular clips are easier to form than circular arc-shaped ones
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 solution maintains precise dimensions and improves motor efficiency while reducing production costs and complexity, enabling efficient and economical manufacturing of electrical machine circuit elements.
Implementation Method 1
the clips are inserted as an interference fit into the seats to lock them together
Data Source
AI summary
An electrical machine circuit element (1) comprises a flat metal sheet (2) provided with a plurality of slots (3) for an electric and/or cooling circuit. The elements (1) presents a plurality of clips (5) which project from the flat metal sheet (2) and a plurality of seats (7) to receive and retain clips (5) of other elements (1), in such a manner as to connect several elements together. Each clip (5) projects from one face of the metal sheet (2) and defines a seat (7) on the opposite face. The clips (5) present an edge (11) facing into the slots (3).