Integrated Rotary Machine Axial Connector Layout
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional mechanically and electrically integrated rotary electric machines face challenges when applied to electric vehicle or hybrid vehicle driving, requiring large cross-sectional area copper busbars for high output AC wiring, leading to increased size and reduced assembly ease due to the need for insulation covers and multiple wires passing through circuit board apertures.
Innovation Solution
A mechanically and electrically integrated rotary electric machine design featuring a cylindrical frame with a motor portion and inverter portion, utilizing an end portion connector near the output shaft to distribute sinusoidal currents and axial connectors parallel to the frame axis, allowing for efficient use of large cross-sectional area AC wiring without increasing overall size and improving assembly ease.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If large cross-sectional area copper busbars are used for high output AC wiring, then the current carrying capacity is improved, but the overall size of the rotary electric machine increases
Solution Approach 1:
The patent transitions from radial arrangement of busbars to axial arrangement, utilizing the axial dimension of the motor portion. The axial connectors extend in the axial direction from the inverter portion through the motor portion to the end portion connector, effectively using the unused axial space to accommodate large cross-sectional area conductors without increasing the radial or overall footprint of the machine.
Solution Approach 2:
The connection path is segmented into two distinct parts: axial connectors that extend from the inverter portion through the motor portion parallel to the axial direction, and an end portion connector located at the end portion of the motor portion. This segmentation allows the large cross-sectional area conductors to be routed axially rather than radially, avoiding interference with the inverter portion mounting region and reducing overall size.
2Reliability
If multiple wires are passed through penetrating aperture portions of the circuit board for AC wiring connection, then the electrical connection is achieved, but the ease of assembly is reduced
Solution Approach 1:
The patent extracts the AC wiring connection function from the circuit board penetrating aperture method. Instead of passing multiple wires through the circuit board, the axial connectors provide a separate, dedicated connection path from the inverter portion through the motor portion to the end portion connector, eliminating the need for complex multi-wire routing through circuit board apertures and significantly improving assembly ease.
Data Source
AI summary
In a mechanically and electrically integrated rotary electric machine, a motor portion and an inverter portion are inserted inside a cylindrical frame. The motor portion has a plurality of coils. The inverter portion has a plurality of switching elements. The coils and the switching elements are electrically connected by a connector. The connector has: an end portion connector that distributes sinusoidal electric currents from the switching elements to the respective coils; and a plurality of axial connectors that direct the sinusoidal electric currents from the switching elements to the end portion connector. The end portion connector is disposed on an end portion of the motor portion near an output shaft. The axial connectors are disposed parallel to an axial direction of the frame so as to pass from the switching elements through a mounted region of the motor portion.