Overmolded Connecting Rings for Rotary Machine Assembly
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Solution Overview
Problem
The manufacturing and assembly of power distribution apparatus for rotary electric machines, such as electric motors or generators, are complex and require multiple components and steps, making the process inefficient and prone to errors.
Innovation Solution
A power connecting apparatus featuring a set of connecting rings with raised portions and an overmolded insulating carrier ring, allowing for simplified assembly by integrating multiple connections into a single unit, with exposed raised portions for welding and insulation of stator coil wires, reducing the need for multiple suppliers and assembly steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional power distribution apparatus with multiple separate components are used, then electrical connection reliability is maintained, but manufacturing complexity and assembly steps increase significantly
Solution Approach 1:
The patent merges multiple separate components (connecting rings, insulating members, and supporting structures) into a single integrated power distribution apparatus. The connecting rings are formed with integral insulating members and supporting structures, eliminating the need for separate assembly steps and reducing manufacturing complexity while maintaining connection reliability through the integrated design.
Solution Approach 2:
The connecting rings in the patent serve multiple functions simultaneously: they provide electrical connections, incorporate insulating members for electrical isolation, include supporting structures for mechanical stability, and feature raised portions for wire insertion. This multi-functionality reduces the number of separate components needed while maintaining all necessary operational requirements.
2Productivity
If multiple separate components and assembly steps are used, then electrical insulation is ensured, but assembly time and production efficiency decrease
Solution Approach 1:
The insulating members are formed as integral parts of the connecting rings through a single molding process, eliminating separate assembly steps. This integration ensures that electrical insulation is built-in during manufacturing rather than added later, improving assembly efficiency while maintaining insulation quality through precise integral formation.
Solution Approach 2:
The insulating members are pre-formed as integral structures during the connecting ring manufacturing process, before assembly occurs. This preliminary action ensures that insulation properties are established during production with high precision, eliminating the need for separate insulation installation steps and improving overall assembly efficiency.
3Manufacturing precision
If complex machining operations are performed, then connection precision is improved, but manufacturing cost and time increase
Solution Approach 1:
The patent employs molding processes to form the connecting rings and insulating members, replacing complex machining operations. The molding process achieves high connection precision through precise parameter control during forming, while significantly simplifying manufacturing and reducing costs compared to traditional machining methods.
Solution Approach 2:
The patent replaces mechanical machining operations with molding processes for forming the connecting rings and insulating members. This substitution eliminates complex machining steps while achieving equivalent or superior precision through the molding process, thereby simplifying manufacturing and reducing production time.
4Device complexity
If multiple suppliers and components are used, then component specialization is achieved, but overall assembly complexity and time increase
Solution Approach 1:
The patent integrates multiple specialized components (connecting rings, insulating members, supporting structures) into a single unified power distribution apparatus. This merging reduces assembly complexity by eliminating the coordination of multiple suppliers and components, while the integral design maintains the functional specialization of each element within the unified structure.
Data Source
AI summary
In some examples, a connecting ring may connect to a stator coil. The connecting ring may include at least one linear conductor integrally formed in a ring-like shape. Further, the connecting ring may include a terminal section integrally formed in the linear conductor, the terminal section including a hole configured to receive a wire end of the stator coil inserted into the hole in an insertion direction. In addition, the connecting ring may include a cylindrical protrusion having an opening in communication with the hole. The cylindrical protrusion may protrude away from the hole in the insertion direction. Additionally, the connecting ring may include bends for raising a first portion of the connecting ring including the terminal section in the insertion direction relative to a second portion of the connecting ring. An insulating member may cover the second portion of the connecting ring.