Molded Stator Power Line Connection for Vibration Durability
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Solution Overview
Problem
The durability of power lines in stators is compromised due to vibrations, particularly at bent portions where they connect to coil end portions and terminal blocks, leading to reduced stiffness and increased stress.
Innovation Solution
The bent portions of the power lines are coated with a resin material to increase geometrical moment of inertia, and the entire assembly is surrounded by a mold portion, including a heat-shrinkable or heat-seal tube, to enhance stiffness and reduce vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the power line is bent to extend in a predetermined direction for connection, then the power line can be connected to the terminal block, but stress is applied to the bent portion due to vibrations, reducing durability
Solution Approach 1:
A coating portion is provided at the bent portion of the power line before the stator undergoes vibration during operation. This coating portion acts as a cushioning element that absorbs and distributes the stress generated by vibrations, preventing stress concentration at the bent portion and thereby maintaining the durability of the power line while preserving its connection capability.
2Strength
If the bent portion is coated to increase geometrical moment of inertia, then stiffness and durability are improved, but the structure becomes more complex
Solution Approach 1:
The coating portion is formed as a composite structure that combines the power line conductor with a coating material layer. This composite structure increases the geometrical moment of inertia of the bent portion, thereby improving stiffness and durability without requiring a completely separate reinforcement structure, thus limiting the increase in structural complexity.
3Stability of the object's composition
If the mold portion surrounds the coil end portion and power line, then the joint is stably fixed, but the bent portion remains vulnerable to vibration-induced stress
Solution Approach 1:
The coating portion is selectively applied only at the bent portion of the power line, providing localized reinforcement and stress distribution exactly where the vibration-induced stress occurs. This local quality approach ensures that the bent portion is protected against vibration damage while the mold portion continues to provide stable fixing of the joint between the coil end portion and the power line.
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 coating improves the durability of the power lines by reducing amplitude during vibrations and maintaining insulation properties, allowing for a more compact design with reduced positional variations.
Implementation Method 1
The bent portions of the power lines are coated with a resin material to increase geometrical moment of inertia
Implementation Method 2
including a heat-shrinkable or heat-seal tube
Data Source
AI summary
A stator includes a core having a yoke having an annular shape, and teeth protruding toward a center of the yoke and provided at predetermined intervals in a circumferential direction of the yoke, a coil disposed to surround the teeth, a power line connected to a coil end portion of the coil, protruding in an axial direction of the core, and having one end and the other end, the power line having a terminal portion connected to the other end opposite to the one end connected to the coil end portion, a bent portion bent to extend in a predetermined direction, and a coating portion coating the bent portion over both ends of the bent portion, and a mold portion surrounding the coil end portion and integrally surrounding the coil end portion, the one end of the power line, and at least part of the coating portion.