External Conductors for Claw Pole Generator Contact Elements
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Solution Overview
Problem
Conventional contact elements in electrical machines require complex and expensive wiring geometries with angular paths, leading to increased line losses and manufacturing complexity, while also risking short circuits.
Innovation Solution
Designing external connection conductors that run directly between arc end areas, potentially in an arc-chord or arc-shaped path, to minimize line losses and simplify manufacturing, with the option of using solid conductors and insulating materials to prevent short circuits and optimize placement within the machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductors are routed through the substrate with an angular path, then short circuits between conductors are avoided, but wiring length increases and line losses increase
Solution Approach 1:
The patent moves the connection path from a two-dimensional substrate plane to a three-dimensional external routing. Conductors are led out of the substrate at angled positions and connected externally, allowing direct linear paths that minimize length while maintaining electrical isolation through the substrate's physical structure.
Solution Approach 2:
The connection function is extracted from the substrate interior to the external environment. By taking out the conductor path from the substrate and routing it externally, the patent eliminates the need for complex angular paths within the substrate while reducing overall wiring length and associated line losses.
2Reliability
If conductors are routed with an angular path through the substrate, then electrical isolation is maintained, but manufacturing complexity and cost increase
Solution Approach 1:
The patent segments the connection system into two distinct parts: the substrate that provides electrical isolation and mounting, and external connection elements that provide direct routing. This segmentation allows each component to be optimized independently - the substrate for isolation and the external connectors for simple, direct paths.
Solution Approach 2:
The complex angular routing function is extracted from the substrate and replaced with simple external connections. This extraction simplifies substrate manufacturing while maintaining electrical isolation through the substrate's inherent structure.
3Loss of energy
If conductors are routed externally instead of through the substrate, then wiring length is reduced and line losses decrease, but conductor protection and positioning become more challenging
Solution Approach 1:
The patent introduces an intermediary connection structure that bridges the substrate and external environment. This intermediary element provides both mechanical support and electrical connection, protecting the conductors while allowing direct routing that minimizes line losses.
Solution Approach 2:
By moving conductor routing to an external three-dimensional space rather than confining it to the two-dimensional substrate plane, the patent achieves shorter paths while using the intermediary connection structure to provide protection and positioning.
Data Source
AI summary
An electrical machine, in particular a generator, preferably a claw pole generator, having a contact element for electrically connecting electrical components, which is made up of a generally arc-shaped, electrically non-conductive substrate having arc end areas, including electrical conductors for connecting the components. At least one of the electrical conductors is designed as an external connection conductor, which runs outside the substrate from one arc end area to the other arc end area.