Rotary Machine Connection Device with Sealed Multi-Radius Plugs
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Solution Overview
Problem
Connecting phase inputs of an electric motor to an electronic power card in an electric supercharger is challenging due to spatial constraints and sealing issues between the turbine and electrical parts, particularly when the power card is larger than the motor's diameter.
Innovation Solution
A connection device with molded metal bars and sealing means, comprising a main plastic part with metal bars connecting first and second plugs at different distances, ensuring electrical connection and sealing between the electronic power card and the electric machine, while allowing for remote welding and protecting electronic components from particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the electronic power card is made larger to accommodate more components, then the electrical connection capability is improved, but the spatial constraints and sealing difficulty worsen
Solution Approach 1:
The patent transitions from a planar connection layout to a three-dimensional configuration by arranging first plugs on the bearing at radius R1 and second plugs on the cover at radius R2, where R2 > R1. This dimensional change allows the electronic power card to be larger while maintaining proper sealing and spatial arrangement, resolving the contradiction between electrical connection capability and spatial constraints.
Solution Approach 2:
The connection device is nested within the housing structure, with the main body mounted on the bearing and the cover enclosing the electronic power card. This nesting arrangement allows the larger power card to be integrated into the compact motor assembly without compromising sealing or spatial constraints.
2Ease of operation
If the phase inputs are positioned closer to the axis to simplify connection, then the connection simplicity is improved, but the sealing performance worsens
Solution Approach 1:
Instead of positioning all plugs at the same radius for simplicity, the patent uses two different radii (R1 for first plugs, R2 for second plugs, where R2 > R1). This dimensional differentiation allows the first plugs to be positioned optimally for sealing near the bearing while the second plugs are positioned outward for easy connection to the larger power card, resolving the contradiction between connection simplicity and sealing performance.
3Reliability
If the first plugs are arranged at a larger radius to improve sealing, then the sealing performance is improved, but the connection complexity to the power card worsens
Solution Approach 1:
The patent resolves the connection complexity by introducing a second radius R2 > R1 for the second plugs on the cover. This allows the first plugs to remain at the optimal sealing radius R1 while the second plugs are positioned at the larger radius R2 for easier connection to the power card, thus improving sealing without increasing connection complexity.
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
The connection device (6) according to the invention is intended for a rotating electrical machine (2) of the type powered via a plurality of first plugs arranged on a bearing (13) of a shaft of the machine (2) at predetermined angular intervals around this shaft at a predetermined first distance. According to the invention, the connection device (6) comprises a plurality of second plugs arranged around said shaft at a predetermined second distance greater than said predetermined first distance and electrically connected to a plurality of first terminals (9) adapted to be connected with said first plugs. In another feature, the connection device (6) comprises a main part (7) made of plastic with a plurality of overmolded metal bars connecting the second plugs and the first terminals.