Vehicular Rotary Electric Machine Intermediate Wiring Stress Buffering
Solution Overview
Problem
Vehicular rotary electric machines face challenges in vibration resistance due to separate mounting of field circuit sections and brush holders, leading to increased load on terminal connecting portions, which affects durability and vibration durability performance.
Innovation Solution
The implementation of an intermediate wiring member with stress buffering mechanism that connects the field circuit section and brush holder, absorbing vibrations and residual stress through an elastic planar face portion, thereby improving vibration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the field circuit section and brush holder are mounted separately to the bracket, then the field circuit section can be positioned to cool switching elements with ambient air while the brush holder can contact the rotor, but the separate mounting causes increased vibration and stress on terminal connecting portions
Solution Approach 1:
An intermediate wiring member is introduced as a mediator between the field circuit section and brush holder. This intermediate member includes flexible wiring that can absorb relative displacement and vibration, thereby resolving the contradiction by maintaining electrical connection while accommodating the separate mounting positions required for cooling and rotor contact.
Solution Approach 2:
The wiring member's physical parameters are changed to be flexible rather than rigid. The flexible wiring can elastically deform to absorb vibration and displacement, allowing the field circuit section and brush holder to be mounted separately for optimal cooling and contact while maintaining reliable electrical connection under vibrational conditions.
2Adaptability or versatility
If the field circuit section and brush holder are mounted separately, then each component can be optimally positioned for its function, but the number of fixing components and fixing area increases
Solution Approach 1:
The intermediate wiring member integrates multiple functions: it provides electrical connection, absorbs vibration, and reduces the need for additional fixing components. By combining these functions into a single component, the solution maintains optimal positioning of the field circuit section and brush holder while reducing overall device complexity.
3Reliability
If rigid connecting terminals are used between field circuit section and brush holder, then electrical connection is stable, but vibration load on connecting portions increases
Solution Approach 1:
The connecting terminal's physical parameter is changed from rigid to flexible. The flexible wiring maintains electrical connection stability while its elasticity allows it to absorb vibration energy, thereby improving vibration durability without sacrificing connection reliability.
Solution Approach 2:
The flexible wiring acts as a pre-designed cushioning element that anticipates and absorbs vibration loads before they can damage the connecting portions. This beforehand cushioning protects the rigid components from vibrational stress while maintaining electrical connectivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The stress buffering mechanism effectively reduces stress on connecting portions, enhancing vibration resistance and durability by dispersing and absorbing vibrations, while also reducing the number of fixing components and fixing area.
Implementation Method 1
an intermediate wiring member with stress buffering mechanism that connects the field circuit section and brush holder, absorbing vibrations and residual stress through an elastic planar face portion
Data Source
AI summary
A vehicular rotary electric machine has a stator and a rotor supported by a bracket; a field winding which is provided on the rotor and is for generating a magnetomotive force; a field circuit section which is for supplying a current to the field winding; and a brush holder having a brush, the field circuit section and the brush holder being separately mounted to the bracket. In the vehicular rotary electric machine, connecting means between the field circuit section and the brush holder is configured by an intermediate wiring member having a stress buffering mechanism.