Rotary Electric Machine Connector Layout for Protected Pin Assembly
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Solution Overview
Problem
Existing rotary electric machines face challenges in efficiently connecting stator windings to the main circuit without using lead wires, which can lead to exposure of connection pins to conductive powders and moisture, and may result in short-circuits or incorrect mounting due to symmetrical pin arrangements.
Innovation Solution
A rotary electric machine design featuring a connecting board with radially outward connection pins, a direct connection connector, and an elastic member, where the connecting board is fixed to the frame using resin molding, allowing direct electrical connection between the stator windings and the main circuit connector without lead wires, and incorporating asymmetrical pin arrangements to prevent incorrect mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connection pins are provided outside the frame, then electrical connection between stator windings and main circuit is achieved, but connection pins are exposed to conductive powders and moisture causing short-circuits
Solution Approach 1:
The direct connection connector is inserted into an opening provided in the frame, nesting the connector within the frame structure. This protects the connection pins from external contaminants while maintaining electrical connection functionality between stator windings and main circuit.
Solution Approach 2:
The direct connection connector acts as an intermediary component that provides a protected interface between the internal stator windings and external main circuit. It mediates the electrical connection while shielding pins from conductive powders and moisture through its housing structure.
2Ease of operation
If symmetrical pin arrangements are used, then ease of assembly is improved, but incorrect mounting cannot be prevented
Solution Approach 1:
The connection pins are arranged asymmetrically on the connecting board, with different positions and configurations that prevent incorrect mounting. This asymmetry ensures that the direct connection connector can only be installed in the correct orientation, eliminating the risk of wrong mounting while maintaining assembly ease through guide structures.
3Adaptability or versatility
If lead wires are used for connection, then flexibility in wiring is improved, but connection complexity and potential failure points increase
Solution Approach 1:
The invention extracts and eliminates the lead wire component from the connection system. By providing direct electrical connection through connection pins mounted on the connecting board, it removes the intermediate lead wire, reducing connection complexity and potential failure points while maintaining necessary adaptability through the connector design.
Solution Approach 2:
The connection pins are integrated directly onto the connecting board, merging the connection function with the existing structural component. This eliminates separate lead wires and reduces the number of components, simplifying the overall connection structure while maintaining electrical connectivity.
Data Source
AI summary
A rotary electric machine includes a rotor rotatable around an axis, a stator provided to surround the rotor and having a first side on one side, a connecting board, a bracket, connection pins electrically connected to the connecting board, a direct connection connector, and a main circuit connector. Stator windings are electrically connected the connecting board which is provided on the one side. The bracket has an opening and is provided on the one side to be connected to the stator so as to cover the connecting board and the first side of the stator. The direct connection connector is inserted into the opening such that the connection pins are inserted into the direct connection connector to be electrically connected to the direct connection connector. The main circuit connector is inserted into the opening and to be electrically connected to the direct connection connector.