Electric Power Collection Ring Assembly with Level Difference Terminals
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Solution Overview
Problem
The existing manufacturing method for electric power collection and distribution rings is complex and prone to deformation of the insulating holder due to high stress, making the assembly process difficult, especially when multiple conductor parts are arranged in parallel.
Innovation Solution
The design features a configuration where the first and third annular conductor parts are coaxially arranged in parallel, with the first feeding terminal part and second feeding terminal part having level difference parts that prevent interference during assembly, allowing for easier and more straightforward assembly of the electric power collection and distribution ring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal part is preliminarily bent exteriorly in the diameter direction before stacking three bus bars, then the insulating holder is protected from excessive stress, but the manufacturing process becomes complex with multiple bending steps
Solution Approach 1:
The terminal part is preliminarily bent exteriorly in the diameter direction before the bus bars are stacked in the insulating holder. This preliminary bending action prevents interference between the terminal part and tubs during assembly, protecting the insulating holder from excessive stress while enabling a streamlined manufacturing process.
2Ease of manufacture
If the tubs are bent interiorly in the diameter direction after stacking three bus bars, then the terminal part interference problem is avoided, but the insulating holder is subjected to large stress causing deformation
Solution Approach 1:
Instead of bending the tubs after stacking, the terminal part is preliminarily bent exteriorly before stacking. This reverses the sequence of operations to perform the bending action when it causes less stress on the insulating holder, thereby avoiding deformation while still preventing interference during assembly.
3Quantity of substance
If the terminal part width is increased to accommodate higher current, then the current carrying capacity is improved, but the bending stress on the insulating holder increases
Solution Approach 1:
The terminal part is preliminarily bent exteriorly before stacking the bus bars. This allows the terminal part to have sufficient width for high current capacity while the bending operation is performed when it exerts less stress on the insulating holder, avoiding deformation.
4Productivity
If multiple annular conductor parts are arranged in parallel in the diameter direction, then the power distribution capability is improved, but interference between protrusions makes assembly difficult
Solution Approach 1:
The terminal part is preliminarily bent exteriorly before stacking the bus bars in parallel arrangement. This preliminary bending prevents interference between the terminal part and tubs of adjacent bus bars, enabling smooth assembly of multiple conductor parts in parallel for efficient power distribution.
Data Source
AI summary
An electric power collection and distribution ring includes first to third bus rings configured to collect and distribute electric power from and to winding wires of a plurality of phases. The first to third bus rings include first to third annular conductor parts, respectively, and first to third feeding terminal parts, respectively, configured to feed electric power to the first to third annular conductor parts, respectively. The second feeding terminal part projects toward another side in an axial direction of the first to the third annular conductor parts without projecting toward the one side in the diameter direction than the first annular conductor part. The third feeding terminal part projects toward the another side in the axial direction of the first to the third annular conductor parts without projecting toward the one side in the diameter direction than the second annular conductor part.