Magneto Generator Lead Wire Bundling and Clamping
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Solution Overview
Problem
Conventional magneto generators require a large number of parts, have a significant axial dimension, and are prone to degradation due to deposits in gaps between the lead clamp and magneto coil, leading to potential lead breakage or disconnection.
Innovation Solution
A magneto generator design with a flywheel and stator core that includes permanent magnets and a three-phase magneto coil, where lead wires are bundled and secured by a lead clamp that covers and presses the lead toward the magneto coil, reducing the axial dimension and preventing deposits, thus minimizing the number of parts and enhancing vibration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual bands are used to secure each lead wire, then vibration resistance of lead wires is ensured, but the number of parts increases
Solution Approach 1:
Multiple individual bands for securing lead wires are merged into a single lead clamp that simultaneously secures multiple lead wires. The lead clamp is fixed to the stator core and clamps all lead wires at once, eliminating the need for separate bands for each lead wire while maintaining vibration resistance.
2Reliability
If a lead clamp is used to clamp the lead, then vibration resistance is ensured, but the axial dimension of the stator increases
Solution Approach 1:
The lead clamp is nested within the stator assembly by fixing it to the stator core, allowing the lead clamp to occupy the same spatial envelope as the stator rather than adding external axial dimension. The lead clamp is positioned radially inward relative to the magneto coil, utilizing the existing stator structure to support the lead securing function.
3Ease of manufacture
If there is a gap between the lead clamp and magneto coil, then assembly is easier, but degraded matter deposits in the gap causing lead breakage
Solution Approach 1:
The potential harmful effect of gap formation is converted into a benefit by designing the lead clamp to press the lead against the magneto coil, intentionally creating contact pressure that eliminates gaps. The pressing action transforms the potential gap-space into a compressed interface that prevents deposit accumulation while maintaining assembly feasibility.
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
The design reduces the number of parts required, minimizes axial dimension, prevents deposition of degraded matter, and enhances vibration resistance, leading to a more reliable and efficient magneto generator.
Implementation Method 1
a magneto generator which generates electricity under the electromagnetic induction action of a permanent magnet and a magneto coil in accordance with the rotation of a flywheel
Data Source
AI summary
In a magneto generator, second phase lead wires (10a, 10b) and third phase lead wires (11a, 11b) among individual one pair of first, second and third lead wires (9a, 9b; 10a, 10b; 11a, 11b) are covered with first protective tubes (12a, 12b), respectively. The second phase lead wires (10a, 10b) and the third phase lead wires (11a, 11b) covered with the first protective tubes (12a, 12b) are bent toward the first phase lead wires (9a, 9b) in a circumferential direction and bundled together with the first phase lead wires (9a, 9b). The first phase lead wires (9a, 9b), the second phase lead wires (10a, 10b) and the third phase lead wires (11a, 11b) thus bundled are bent in a direction opposite to the circumferential direction and covered with second protective tubes (22a, 22b, 22c), respectively.