Rotary Electric Machine Conductive Pillar Cable Routing
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Solution Overview
Problem
The existing assembly methods for rotary electric machines are prone to damaging power cables and pose safety risks to operators due to manual handling and welding, leading to reduced reliability and increased assembly time.
Innovation Solution
A rotary electric machine design featuring a housing with conductive pillars that penetrate through a notch in the rotor's end cover, allowing for secure and efficient electrical coupling of power cables, reducing manual handling and enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If power cables are manually pulled through perforations of the end cover, then the assembly can be completed, but the power cables are prone to scratching or damage
Solution Approach 1:
The patent introduces an intermediary component (guide structure or protective channel) between the cable and the perforation edges. This intermediary element mediates the interaction by providing a protected path for the cable to pass through, preventing direct contact with sharp edges that cause damage, thus resolving the contradiction between ease of manual installation and cable integrity.
Solution Approach 2:
The patent applies beforehand cushioning by providing protective features (such as rounded edges, guide flutes, or cushioning material) at the perforation locations before the cable installation process. These pre-installed protective features cushion the cable during the pulling operation, preventing scratching and damage while maintaining the simplicity of manual installation.
2Productivity
If operator manually assembles stator and rotor and performs wire-drawing operations simultaneously, then assembly can be completed, but operator's hands are at risk of crushing or injury
Solution Approach 1:
The patent segments the assembly process into distinct stages: first assembling the stator and rotor without cables, then separately installing the power cables through pre-prepared perforations. This segmentation separates the hazardous wire-drawing operation from the assembly operation, allowing the operator to complete assembly first and handle cables later when hands are not in the crushing zone, thus maintaining productivity while improving safety.
Solution Approach 2:
The patent applies preliminary action by pre-drilling and preparing the perforations in the end cover before assembly, and pre-positioning the cable routing paths. This preliminary preparation eliminates the need for simultaneous wire-drawing during assembly, allowing operators to complete the mechanical assembly first and then safely install cables without hand injury risk.
3Reliability
If power cables are manually welded to circuit board, then electrical coupling is achieved, but assembly time increases
Solution Approach 1:
The patent replaces the manual welding process with a mechanical connection system. Instead of requiring time-consuming welding operations, the design uses pre-attached connectors, plug-and-play interfaces, or snap-fit electrical connections that achieve reliable electrical coupling through mechanical means, significantly reducing assembly time while maintaining connection quality.
Solution Approach 2:
The patent applies preliminary action by pre-welding or pre-attaching the power cable connectors to the circuit board before the final assembly stage. This preliminary electrical connection preparation eliminates the need for on-site welding during assembly, reducing assembly time while ensuring reliable electrical connections through factory-controlled welding processes.
Data Source
AI summary
The present disclosure provides a rotary electric machine including a housing, a stator, a rotor, an outer cover and a plurality of power cables. The stator is disposed in the housing and includes a stator core, a plurality of windings, a circuit board and a plurality of conductive pillars. The plurality of windings are wound around the stator core. The circuit board is fixed on the top of the stator core. The plurality of conductive pillars are electrically coupled with the circuit board. The rotor includes and an end cover. The end cover is disposed between the outer cover and the housing. The plurality of conductive pillars partially penetrate through a notch of the end cover, respectively. Two ends of each of the plurality of power cables are electrically coupled with the corresponding one of the plurality of conductive pillars and a connector, respectively.