Motor Wiring Connector Geometry for Compact Bendable Terminals
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Solution Overview
Problem
Existing rotating electrical machine wiring components face challenges in bending conductor wires near flat plate-shaped connecting portions without increasing the component's size, and in maintaining accurate connection to windings while avoiding distortion.
Innovation Solution
A rotating electrical machine wiring component with a conductor wire that has a flat plate-shaped connecting portion and a bent portion near it, where the conductor wire is not insulated at these points, allowing for efficient bending and connection to the winding while maintaining a compact size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the conductor wire is bent at a portion covered with insulation, then the wiring component can connect the winding to the terminal block while avoiding contact with surrounding members, but the insulation may become partially thin due to heat of welding and the distance between the portion to be welded and the bent portion needs to be long, resulting in an increase in size of the wiring component
Solution Approach 1:
The patent applies local quality by creating a non-insulated portion specifically at the bending location. This localized change in insulation coverage allows the conductor wire to be bent without the insulation becoming thin or damaged, while maintaining adequate distance from the welding portion. The selective removal of insulation at the bend location enables compact wiring component design without compromising the ability to avoid surrounding members.
2Ease of operation
If the portion formed in a plate shape with the insulation removed is bent, then the wiring component can be configured to connect the winding to the terminal block, but a portion to be connected to the winding may become distorted depending on the bending direction, causing problems in connection with the winding and restricting the bending direction, resulting in an increase in size of the wiring component
Solution Approach 1:
The patent applies segmentation by dividing the conductor wire into distinct functional portions: an insulated portion for general routing, a non-insulated bent portion for directional flexibility, and a non-insulated connecting portion for precise welding. This segmentation allows the bent portion to be formed in a specific direction without distorting the connecting portion, as they are functionally and spatially separated. The bent portion can achieve the needed flexibility while the connecting portion maintains its precision for accurate winding connection.
3Length of stationary object
If the conductor wire is not covered with insulation at the connecting portion and bent portion, then the conductor wire can be bent near the connecting portion without increasing the component's size, but the conductor wire requires additional processing to remove insulation at specific locations
Solution Approach 1:
The patent applies preliminary action by removing the insulation from the bent portion and connecting portion before the bending and forming operations. This preliminary insulation removal prevents the insulation from interfering with the bending process and ensures that the conductor wire can be shaped to the required configuration. By performing the insulation removal in advance, the subsequent bending and forming operations can proceed without additional complexity, and the overall component length can be optimized.
Data Source
AI summary
A rotating electrical machine wiring component is configured to be connected to an armature winding of a rotating electrical machine and includes a conductor wire comprising a conductive metal, and an insulation covering a portion of the conductor wire, wherein the conductor wire comprises a flat plate-shaped connecting portion located at one end and connected to the armature winding, and a bent portion bent by a bending process in a vicinity of the connecting portion, wherein the conductor wire is not covered with the insulation at the connecting portion and the bent portion, and wherein a cross-sectional shape of the conductor wire in a cross-section perpendicular to an extending direction of the conductor wire is rectangular at the connecting portion and circular at the bent portion.