Wound Rotor Synchronous Motor Fusing Terminal Design
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Solution Overview
Problem
Wound rotor synchronous motors face challenges in securing sufficient insulation distance and working space without increasing the motor's overall length, particularly during the fusing process of the rotor coil connections.
Innovation Solution
The design incorporates a fusing terminal with a fixing portion and a connection portion that are twisted and bent in specific directions to receive fusing pressure perpendicular to the rotation shaft's axis, allowing for connection within the existing motor dimensions without requiring additional length or working space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the motor length is reduced to improve compactness, then the overall size decreases, but the insulation distance between fusing terminal and coil winding portion becomes insufficient
Solution Approach 1:
The fusing terminal is designed with a bent configuration that utilizes the radial dimension (width direction of terminal mounting portion) to achieve the necessary insulation distance, rather than extending in the axial direction. This dimensional reorientation allows the motor length to be reduced while maintaining adequate insulation clearance between the fusing terminal and coil winding portion.
Solution Approach 2:
The fusing terminal is pre-formed with a bent shape and twisted connection portion before installation. This preliminary configuration ensures that when the terminal is mounted, the insulation distance is already established, eliminating the need for additional axial space during the fusing operation and allowing compact motor design.
2Length of moving object
If the motor length is reduced to improve compactness, then the overall size decreases, but the working space for fusing machine interference avoidance becomes insufficient
Solution Approach 1:
The fusing operation is reoriented to apply pressure in the width direction of the terminal mounting portion rather than in the axial direction. This dimensional change allows the fusing machine to access and fuse the terminal without requiring additional axial working space, enabling compact motor design while maintaining manufacturability.
Solution Approach 2:
The fusing terminal is pre-configured with a bent shape and twisted connection portion that positions the fusing location away from rotor parts. This preliminary arrangement ensures that when the terminal is installed, the fusing machine can operate in the width direction without interfering with rotor components, eliminating the need for extra axial working space.
3Reliability
If the fusing terminal is positioned to maintain insulation distance, then reliability improves, but the motor length increases
Solution Approach 1:
Instead of extending the motor length axially to accommodate insulation distance requirements, the fusing terminal is bent to achieve the necessary clearance in the radial dimension (width direction of terminal mounting portion). This dimensional substitution allows insulation distance to be maintained while keeping the motor length compact.
Solution Approach 2:
The fusing terminal is pre-formed with a bent configuration that establishes the required insulation distance before installation. This preliminary shaping ensures that when the terminal is mounted, the insulation clearance is already achieved without requiring additional axial space, preventing motor length increase.
4Strength
If the fusing pressure is applied in the axial direction, then the connection strength improves, but the motor length increases due to required working space
Solution Approach 1:
The fusing pressure application direction is changed from axial to the width direction of the terminal mounting portion. This dimensional reorientation maintains effective connection strength while eliminating the need for additional axial working space, allowing compact motor design without compromising joint integrity.
Solution Approach 2:
The fusing terminal is pre-configured with a bent shape and twisted connection portion that orients the connection surface perpendicular to the axial direction. This preliminary arrangement enables the fusing machine to apply pressure in the width direction, achieving strong connections without requiring extra axial working space.
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 configuration ensures a sufficient insulation distance between the fused portion and the coil winding, reducing the motor's length by eliminating the need for extra space to avoid interference between the fusing machine and rotor parts.
Implementation Method 1
The fusing terminal is compressed by a fusing machine in a state of supporting a positive connection terminal and negative connection terminal of the rotor coil, and is welded to the rotor coil by resistance welding.
Data Source
AI summary
A rotor of a wound rotor synchronous motor includes: a rotor body coupled to a rotation shaft and around which a rotor coil is wound; and a slip ring module mounted on one portion of the rotation shaft, the slip ring module comprising a brush contact portion configured to contact a brush, a terminal mounting portion connected to the brush contact portion, and a fusing terminal mounted at an exterior circumferential surface of the terminal mounting portion and connected to the rotor coil.