Rotary Electric Machine Inter-Pole Gap Connection

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Solution Overview

Problem

Conventional rotary electric machines with multiple magnetic poles often have a large axial size due to the extended lead wires and stacked terminal blocks, which increases the overall size of the device.

Innovation Solution

The connection portions between conductive members and coil ends are arranged in the inter-pole gaps between magnetic poles, utilizing these gaps for electrical insulation and compactness, allowing for a more compact design by minimizing the axial length.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If lead wires are extended and terminal blocks are stacked in conventional rotary electric machines, then electrical connection is ensured, but the axial size becomes large

Engineering Contradiction:

Improveelectrical connectionVSAvoidaxial size

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

The connection portions are relocated from the axial direction to the radial direction by placing them in the inter-pole gaps between adjacent magnetic poles. This dimensional shift allows electrical connections to be made in the radial plane rather than extending axially, thereby reducing the axial length of lead wires and eliminating the need for stacked terminal blocks while maintaining reliable electrical connectivity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The connection portions are nested within the inter-pole gaps of the magnetic pole structure. By utilizing the existing spatial gaps between magnetic poles for housing connection portions, the design eliminates the need for separate axial extensions and terminal block stacks, achieving compact integration without compromising electrical connection reliability.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Length of moving object

If connection portions are arranged in inter-pole gaps, then axial size is reduced, but electrical insulation must be maintained

Engineering Contradiction:

Improveaxial sizeVSAvoidelectrical insulation

Core Design Contradiction:

Length of moving objectVSReliability

Solution Approach 1:

Resin layers are introduced as intermediary materials between the connection portions and the magnetic poles. These resin layers provide the necessary electrical insulation while allowing the connection portions to be positioned within the inter-pole gaps, thus maintaining both compact axial dimensions and reliable electrical insulation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Thin resin films or layers are applied to the magnetic poles or connection portions to provide electrical insulation. These thin insulating layers enable the connection portions to be placed in the inter-pole gaps without compromising insulation, achieving both miniaturization and electrical safety.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS11323002B2Rotary electric machine

Publication Date: 2022.05.03 DENSO CORP

AI summary

A rotary electric machine includes magnetic poles to which a coil is attached. A connection portion between a conductive member and a coil end of the coil is arranged in an inter-pole gap between the magnetic poles. The rotary electric machine may include a rotor and a stator. The magnetic poles may be magnetic poles of the stator.