Rotary Electric Machine Interconnector Bearing Mount
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Solution Overview
Problem
High-power reversible rotating electrical machines face deterioration of electrical connections due to severe vibration environments, particularly in motor vehicle applications where the interconnector between the stator and power modules is prone to failure.
Innovation Solution
A robust interconnector configuration is introduced, where the interconnector is fixed to a transverse wall of the bearing using fastening members, with threaded inserts for easy disassembly and reliability, and indexed with the bearing and electrical control module to maintain stability and reduce heating, while allowing for easy assembly and vibration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the interconnector is used to establish electrical connection between phase outputs and power modules, then electrical connectivity is achieved, but the connection deteriorates under severe vibration
Solution Approach 1:
The interconnector is merged with the bearing assembly by fixing it to the transverse wall of the bearing. This integration ensures that the interconnector moves together with the bearing, reducing relative motion and vibration-induced stress on the electrical connections between phase outputs and power modules.
Solution Approach 2:
The interconnector is pre-positioned and fixed to the bearing's transverse wall before assembly completion. This preliminary positioning ensures proper alignment and reduces the risk of connection deterioration during subsequent assembly operations and under vibration during operation.
2Reliability
If the interconnector is fixed to the bearing with fastening members, then vibration resistance is improved, but assembly complexity increases
Solution Approach 1:
The bearing's transverse wall serves multiple functions: it provides mechanical support for the bearing, provides a mounting surface for the interconnector, and maintains positional relationship between the interconnector and rotor. This multi-functionality reduces the need for additional separate mounting structures.
3Temperature
If the interconnector is positioned away from the stator body, then heating is minimized, but connection length increases
Solution Approach 1:
The interconnector is extracted from the traditional position near the stator body and repositioned to the bearing's transverse wall. This separation removes the interconnector from the high-temperature zone near the stator windings, minimizing thermal heating while the bearing's location maintains acceptable connection lengths.
Data Source
Figure 1~2
Figure 3~4
Figure 5a~5b
AI summary
The invention mainly relates to a rotary electric machine (10), in particular for a motor vehicle, comprising: - a bearing (17) having a transverse wall (46), - a stator having a body and a coil provided with a plurality of phase windings, each phase winding comprising ends, - an electric control module of the rotary electric machine, - an interconnector (41) comprising terminals intended to be connected to the ends of the phase windings and connection terminals (49) intended to be connected to the electric control module of the rotary electric machine (10), characterized in that - the interconnector (41) bears against a face of the transverse wall (46) of the bearing (17) directed toward the interior of the rotary electric machine, - the interconnector (41) being attached to said face of the transverse wall (46) of the bearing by means of attachment members (56).