Dynamoelectric Rotor Output Wire Securing via Magnetic Pole Support
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Solution Overview
Problem
Conventional automotive alternator rotors face issues with output wire durability due to high centrifugal forces and temperature-induced deformation, leading to wire breakage and reduced durability.
Innovation Solution
A dynamoelectric rotor design where the centrifugal force acting on the output wire securing portion is borne by claw-shaped magnetic pole portions, preventing deformation and enhancing wire durability by mounting the resin bobbin such that the radially-outermost portion of the output wire securing portion contacts the inner circumferential wall surface of the claw-shaped magnetic pole portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the output wire securing portion is made from resin bobbin material, then insulation and heat resistance are improved, but centrifugal force causes deformation and wire breakage
Solution Approach 1:
The invention merges the output wire securing portion with the claw-shaped magnetic pole portions by making them integrally formed from the same resin material. This integration allows the magnetic pole portions to structurally support the securing portion against centrifugal forces while maintaining the resin's insulation and heat resistance properties.
Solution Approach 2:
The invention uses a resin material that combines insulating and heat-resistant properties with structural strength to withstand centrifugal forces. The resin is molded to create both the securing portion and magnetic pole portions as a composite structure that satisfies both electrical requirements and mechanical strength requirements.
2Power
If the rotor operates at high rotational speeds, then power output is improved, but centrifugal force increases and causes wire breakage
Solution Approach 1:
The invention merges the load-bearing function into the magnetic pole portions, which are integrally formed with the securing portion. The claw-shaped magnetic pole portions act as structural supports that bear centrifugal forces, enabling the rotor to operate at high speeds without wire breakage while maintaining high power output.
3Temperature
If the output wire securing portion is exposed to high temperatures, then heat resistance is tested, but deformation increases and durability decreases
Solution Approach 1:
The invention uses a resin material with high heat resistance that maintains dimensional stability under thermal stress. The material is engineered to withstand temperatures up to 200°C while preserving both its insulating properties and structural integrity, preventing deformation that would lead to wire breakage.
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 effectively suppresses deformation of the output wire securing portion, preventing wire breakage and improving the durability of the output wires by distributing the centrifugal force through the claw-shaped magnetic pole portions, even at high temperatures.
Implementation Method 1
large centrifugal forces act on the output wires of the rotor... the output wire securing portion is subjected to the centrifugal force that acts on the output wires in addition to the centrifugal force that acts on the output wire securing portion itself
Data Source
AI summary
A resin bobbin is mounted to a pole core by fitting a body portion thereof over first and second boss portions. A rotor coil is configured by winding a conducting wire onto the bobbin, and an output wire of the conducting wire that is led out from the wound portion is wound doubly onto an output wire securing portion of the bobbin. An edge portion of a radially-outermost surface of the output wire securing portion near the body portion is placed in contact with an inner circumferential wall surface of a first claw-shaped magnetic pole portion.