Rotary Electric Machine Cast Interface for Weld-Free Mounting
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Solution Overview
Problem
The conventional attaching parts for rotary electric machines in railway vehicles require multiple welding steps, leading to increased production time and complexity due to the need for extensive inspection and assembly.
Innovation Solution
The use of casted interfaces, such as the upper and lower attaching parts, stator coupling parts, and stoppers, which are integrated with the stator holding plates to simplify the production process and enhance reliability by eliminating the need for extensive welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple welding steps are used to produce the attaching part, then the attaching part achieves adequate strength to support the rotary electric machine, but the production time increases due to multiple welding and inspection steps
Solution Approach 1:
The patent merges multiple separate constituent members into a single integrated attaching part through die-casting. This combining of multiple welded components into one monolithic structure eliminates the need for multiple welding steps and intermediate inspections, thereby reducing production time while maintaining the structural strength required to support the rotary electric machine
2Strength
If multiple constituent members are coupled by welding to form the attaching part, then the attaching part can be produced with adequate strength, but the number of production steps and inspection steps increases
Solution Approach 1:
The patent combines multiple constituent members into a single integrated attaching part produced by die-casting. This merging eliminates the sequential welding operations and associated inspection steps, thereby improving production efficiency while ensuring the attaching part maintains adequate strength through its integrated structure
3Strength
If a complicated shape is used for the attaching part to support the rotary electric machine, then adequate strength and fixation are achieved, but the manufacturing complexity increases
Solution Approach 1:
The patent changes the manufacturing method from traditional welding of multiple components to die-casting of a single integrated part. This parameter change in the manufacturing process allows the production of complicated shapes with adequate strength directly from molten metal, simplifying manufacturing by eliminating the need to assemble multiple pieces while maintaining the complex geometry required for proper fixation
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
This approach reduces production time and costs by simplifying the assembly process while ensuring high accuracy and rigidity of the attachment, allowing for effective cooling and robust fixation to the underframe.
Implementation Method 1
produced by pouring molten metal and solidifying it
Implementation Method 2
providing effective cooling through air passages and heat dissipation
Data Source
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AI summary
There is provided a rotary electric machine (11; 11A) including a rotor (21), an annular stator (22), a pair of annular stator holding plates (47, 48), and an interface (52, 71, 72, 73). The stator is formed of a plurality of stacked magnetic plates outside of the rotor. The pair of stator holding plates (47, 48) is disposed on both sides of the stator (22) in a stack direction. The interface (52, 71, 72, 73) is fixed to an outer circumferential surface of the stator (22) to couple the pair of stator holding plates together, fixes the stator (22) at a rotary-electric-machine attachment position, and has a casted structure continuous from a fixation surface on the outer circumferential surface of the stator to a fixation surface at the rotary-electric-machine attachment position.