Rotary Electric Machine Radial Terminal Connections
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Solution Overview
Problem
Conventional rotary electric machines face challenges in reducing axial dimensions and minimizing parts due to insulation requirements and large bending radii in stator windings, leading to increased axial length and complexity.
Innovation Solution
The configuration of armature windings with conductor terminals extending from radially innermost and outermost positions, directly joining terminals to eliminate crossover portions and busbars, allowing for reduced axial dimensions and fewer parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conductor terminals are connected by passing axially outside the coil end group, then connections can be made between radially innermost and outermost positions, but insulation members are required and axial length increases
Solution Approach 1:
The patent changes the connection path from axial direction to radial direction. Conductor terminals are bent radially inward and connected within the radial plane rather than passing axially outside the coil end group, eliminating the need for insulation members and reducing axial length.
Solution Approach 2:
The patent merges the connection function directly into the conductor terminal structure by bending the terminals radially inward to make contact, eliminating the need for separate insulation members and busbars, thus reducing part count and axial dimensions.
2Ease of manufacture
If conductor terminals are bent radially inward to pass axially outside the coil end group, then connections can be established, but large bending radius is required which increases axial length
Solution Approach 1:
The patent changes the bending direction from axial to radial. Conductor terminals are bent radially inward with a small bending radius to reach adjacent terminals, avoiding the large axial bending radius requirement and reducing overall axial length.
Solution Approach 2:
The patent changes the bending radius parameter by transitioning from large-radius axial bending to small-radius radial bending, making the conductor terminal configuration more compact and reducing axial dimensions.
3Ease of manufacture
If busbars are used to connect conductor terminals, then connections can be made, but the number of parts increases
Solution Approach 1:
The patent merges the connection function directly into the conductor terminal structure by bending terminals radially inward to make direct contact. This eliminates the need for separate busbars and insulation members, reducing the number of parts and simplifying the overall structure.
Solution Approach 2:
The patent extracts and eliminates unnecessary intermediate components (busbars and insulation members) by implementing direct terminal-to-terminal connections through radial bending, simplifying the structure and reducing part count.
Data Source
AI summary
Winding bodies are configured such that radially inner terminals of a conductor wire extend outward at a first axial end of an armature core from a radially innermost position inside slots, and radially outer terminals of the conductor wire extend outward at the first axial end of the armature core from a radially outermost position inside the slots, and respective phase windings of an armature winding are configured by directly joining together the radially inner terminals and by directly joining together the radially outer terminals of the winding bodies that constitute identical phases.