Hydrogenerator Winding Bar Connection Using One-Piece Eyelet
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical machine designs, such as doubly-fed asynchronous machines, face challenges with elongated end windings and increased material costs due to unnecessary bends and complex multi-part connecting elements, which complicate assembly and reduce mechanical stability.
Innovation Solution
A one-piece, radially oriented round eyelet connecting element with intersecting contact surfaces is used to connect winding bars, eliminating the need for additional bends and minimizing copper usage, allowing for simplified assembly and enhanced mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a second bend is made at the rod ends to align them parallel, then the winding bars can be connected, but additional copper material is required which increases material costs and axial length
Solution Approach 1:
Instead of bending the rod ends parallel to each other and connecting them, the invention inverts the approach by keeping the rod ends crossing and using a connecting element that adapts to this natural crossing configuration. This eliminates the need for additional copper material in parallel rod ends while achieving the same electrical connection.
Solution Approach 2:
The connecting element is designed with specific geometric parameters (opening angle, contact surface orientation) that match the crossing angle of the winding bars. By changing the parameters of the connecting element to accommodate the natural crossing configuration, the need for additional material is eliminated.
2Ease of manufacture
If rod ends are bent parallel and connected with connecting parts, then electrical connection is achieved, but the axial length of the end winding increases
Solution Approach 1:
The invention inverts the conventional approach by not bending rod ends parallel but instead using them in their natural crossing configuration. This reduces the axial length requirement while maintaining electrical connection capability.
Solution Approach 2:
The connecting element is designed with contact surfaces oriented at specific angles to the opening direction, allowing electrical connection in a configuration that minimizes axial length. The three-dimensional geometry of the connecting element accommodates the crossing bars more efficiently than linear parallel connections.
3Adaptability or versatility
If multi-part connecting elements are used to connect crossing ends, then adaptability to different crossing angles is achieved, but manufacturing and assembly complexity increases
Solution Approach 1:
The invention merges multiple functions into a single one-piece connecting element: the body provides structural support, the opening accommodates different crossing angles, and the contact surfaces provide electrical connection. This unified structure eliminates the complexity of assembling multiple separate components while maintaining adaptability.
Solution Approach 2:
The connecting element is designed as a universal component that can accommodate different crossing angles through its geometric design (opening angle, contact surface orientation). This single universal element replaces the need for multiple specialized components for different connection scenarios.
4Adaptability or versatility
If complex multi-part connecting elements are used, then different crossing angles can be accommodated, but assembly effort increases
Solution Approach 1:
By combining all necessary connection functions into a single pre-fabricated element, the assembly process is simplified to a single insertion and connection operation. This eliminates the multiple assembly steps required for multi-part connecting elements, significantly improving productivity.
Solution Approach 2:
The connecting element is pre-fabricated with the correct geometry (opening angle, contact surface orientation) to match the required crossing angle. This preliminary preparation eliminates the need for on-site adjustment or complex assembly operations, allowing for rapid installation.
Data Source
Figure 1
Figure 2
Figure 3~4c
AI summary
The invention relates to an electric machine, particularly an asynchronous three-phase current hydrogenerator, having a rotor and a stator and a winding comprising a plurality of winding bars (17, 18) running in the axial direction and resting in pairs on top of each other in corresponding winding slots of a yoke, the winding bars (17, 18) extending out of the winding slots at the faces of the machine and for the most part being electrically connected to each other in pairs according to a prescribed pattern in a winding head (13a), a lower winding bar (18) in a first winding slot and an upper winding bar (17) in a second winding slot each being bent toward each other such that the ends (21, 22) thereof lie one over the other and cross each other in the radial direction. The production and assembly of such a machine are made simplified in that a one-piece connecting element (27) is provided for connecting the winding bars (17, 18) of an electrically connected winding bar pair.