Rotating Electric Machine Connecting Plate Structure
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Solution Overview
Problem
Conventional rotating electric machines face issues with strength and rigidity under high mechanical loads, particularly in high-output and heavy-weight applications, and struggle with sealing and fixing structures that lead to increased size and weight, making them unsuitable for small-size, high-output requirements in electric vehicles.
Innovation Solution
A rotating electric machine design featuring a metal frame with an integrally molded annular fixing member and connecting plate structure, utilizing metal-to-metal bonding and a compact, high-strength configuration that includes insulators and a coil wound around an iron core, allowing for secure fixation without large-scale production facilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a resin leg-shaped portion is used for fixing the connecting plate, then the structure is simple and easy to manufacture, but the strength and rigidity are insufficient under high mechanical loads
Solution Approach 1:
The invention uses a composite structure combining resin (holder) and metal (fixing member with annular portion) to achieve both ease of manufacture and high strength. The metal fixing member provides the necessary mechanical strength while the resin holder provides electrical insulation and structural support, resolving the contradiction between ease of manufacture and strength under high mechanical loads.
2Shape
If the stator is contained in a molding die for integral molding, then the connection structure is compact, but the plant becomes large-scale and sealing becomes difficult
Solution Approach 1:
The invention divides the fixing structure into separate components: a holder and a fixing member with an annular portion. This segmentation allows the stator to be assembled without requiring containment in a large molding die, enabling compact design while simplifying the manufacturing process and improving sealing capability through separate assembly steps.
3Strength
If the connecting plate is upsized to increase fixing strength, then the strength under mechanical load improves, but the overall machine size and weight increase
Solution Approach 1:
The invention changes the material parameter from resin to metal for the fixing member, and introduces an annular geometric parameter that provides high fixing strength with minimal size increase. The annular portion of the fixing member engages with the stator to provide enhanced mechanical coupling without significantly increasing the overall machine size or weight.
Data Source
AI summary
A fixing member (14) formed of an annular metal material is molded integrally with a connecting plate (13) to constitute a connecting plate structure (9), said connecting plate (13) consisting of a plurality of bus bars (11) and a holder (12) for fixing and holding the bus bars. The fixing member (14) has an annular portion (14a) touching a frame (8) for holding a stator (4), and the connecting plate structure (9) is fixed to the frame (8) by the whole or a part of the surface of the annular portion.