Rotor Electrical Connector Guiding Element
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Solution Overview
Problem
The production of separately excited rotors for rotary electric machines is complicated by the need to shape electrical connectors during insertion, which increases manufacturing time and cost.
Innovation Solution
A rotor design featuring a guiding element that elastically deforms the electrical connector to facilitate its insertion within the rotor shaft, eliminating the need for shaping and allowing for automated assembly, with the connector being overmolded for insulation and connected via a hook or fork for easy connection to the field coil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the electrical connector is inserted without shaping during insertion, then the manufacturing complexity is reduced, but the connector cannot be properly positioned within the rotor shaft
Solution Approach 1:
The electrical connector is pre-formed with a curved portion and elastic deformation capability before insertion. The guiding element is pre-installed in the rotor shaft to automatically deform the connector during insertion, eliminating the need for shaping operations during assembly.
Solution Approach 2:
A guiding element is introduced as an intermediary component between the electrical connector and the rotor shaft. This guiding element facilitates the automatic deformation and positioning of the connector during insertion, simplifying both manufacturing and assembly operations.
2Ease of operation
If manual shaping of the electrical connector is performed during insertion, then proper positioning is achieved, but production time increases
Solution Approach 1:
The electrical connector is designed with elastic properties that enable it to self-deform during insertion through the guiding element. The connector automatically shapes itself to the required configuration without requiring manual intervention or external shaping tools, thereby reducing production time.
Solution Approach 2:
The connector is pre-designed with the necessary elastic characteristics and curved geometry to enable automatic deformation during insertion. This preliminary design allows the connector to self-position without time-consuming manual shaping operations.
3Strength
If the electrical connector is rigid, then structural strength is maintained, but it cannot be automatically deformed during insertion
Solution Approach 1:
The electrical connector is designed with controlled elastic properties that allow temporary deformation during insertion while maintaining sufficient structural strength for electrical connection. The material parameters are optimized to balance flexibility for automatic deformation with strength for reliable electrical contact.
Solution Approach 2:
The connector transitions from a rigid state during manufacturing to a dynamically deformable state during insertion. The elastic properties enable the connector to adapt its shape during the insertion process while maintaining structural integrity for its electrical function.
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
This design simplifies the manufacturing process by automating the connector's placement, reducing production time and cost, while ensuring reliable electrical connections and insulation.
Implementation Method 1
at least one guiding element configured to mechanically guide the electrical connector towards the corresponding end of the field coil by deforming the electrical connector from a first state into a second state, in particular by elastically deforming the electrical connector from the first state into the second state
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention concerns a rotor (1) comprising a rotor shaft (4), a rotor body (2) formed of a stack of laminations, a field coil (3) wound around the rotor body (2), at least one slip ring (5) being electrically connected to an end of the field coil (3) through an electrical connector (110), and at least one guiding element (120) configured to mechanically guide the electrical connector (110) towards the corresponding end of the field coil (3) by deforming the electrical connector (110) from a first state into a second state in which the electrical connector (110) comprises an axial portion (113) passing through an axial bore (41) of the rotor shaft (4) and a curved portion (114), an end of the curved portion (114) passing through a through bore (42) of the rotor shaft (4) facing the corresponding end of the field coil (3).