Rotating Electric Machine Sealed Connector for Oil Contamination
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Solution Overview
Problem
High-power reversible rotating electrical machines operating in alternator and motor modes, when coupled with a gearbox, face contamination of gearbox oil with copper particles from contact zones between phase outputs and connector traces, leading to potential pollution of the electrical control module and gearbox oil.
Innovation Solution
A sealed system is implemented using a seal and plug arrangement that tightly mounts between the connector and bearing, featuring openings for phase outputs and a cap to prevent coolant ingress, with insulating material to create a sealed volume around the contact zones, preventing oil and copper particle contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the electric machine is cooled by contact with gearbox oil, then cooling efficiency is improved, but the oil becomes polluted with copper particles from contact zones
Solution Approach 1:
The patent divides the machine into separate sealed zones: the cooling zone where oil contacts the machine exterior, and the protected zone containing copper contact elements. sealing elements create distinct compartments that allow cooling while preventing contamination
Solution Approach 2:
sealing elements act as intermediaries between the cooling oil and copper contact zones, allowing thermal management while blocking contamination. The seals enable heat transfer benefits without direct contact between oil and copper particles
2Reliability
If copper traces are exposed for welding connections, then electrical connectivity is improved, but copper particles contaminate the gearbox oil
Solution Approach 1:
The patent extracts the copper traces from the oil-exposed environment by enclosing them within sealed zones. The sealing elements create protected spaces where copper connections can be made without risking contamination of the surrounding gearbox oil
Solution Approach 2:
sealing elements (including membranes and gaskets) create thin protective barriers that enclose copper contact zones. These flexible or rigid seals maintain the integrity of the protected zone while allowing the machine to function normally
3Object-affected harmful factors
If seals are added to protect contact zones, then oil pollution is prevented, but device complexity increases
Solution Approach 1:
The sealing elements serve multiple functions simultaneously: they prevent oil contamination, define sealed zones for pressure differentials, and provide structural support for electrical connections. This multi-functionality reduces the need for separate components
Solution Approach 2:
The patent merges the sealing function with existing structural elements of the machine. sealing elements are integrated into the housing, connector designs, and mounting structures, combining protection with structural requirements
Data Source
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AI summary
The invention relates to a rotary electric machine, comprising: - a stator comprising a winding having a phase output (68), - a bearing (17) comprising a central opening for passage of a shaft, - a connector (71) comprising at least one trace (72), the connector (71) comprising a hole (78) for passage of said phase output (68) into which said end (73) leads, a sealing gasket (91) being axially arranged between said conductor (71) and said bearing (17) so as to close said hole (78), the gasket (91) comprising an opening (92) for passage of said phase output (68), said gasket (91) being arranged to prevent a cooling liquid from passing from the inside of said rotary electric machine to the contact area (74) between the end (73) of said trace (72) and said phase output (68).