Stacked Interconnection Element for Polyphase Stator Coils
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Solution Overview
Problem
Existing interconnection devices for polyphase rotating electrical machines, such as alternator-starters, face complexity in multiple connection configurations, requiring simplified and flexible solutions to connect coils efficiently across various voltage and network conditions.
Innovation Solution
An interconnection element with stacked conductive layers, including solid annular base layers and additional half-ring layers, provides internal and external connection tabs for secure and adaptable electrical connections, allowing for various configuration options without electrical contact between layers, and featuring a design that protects internal tabs and facilitates angular distribution of connection points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional interconnection devices are used for polyphase rotating electrical machines, then electrical connections can be established, but the connection process becomes complex and cable distances increase when multiple connection configurations are required
Solution Approach 1:
The interconnection device is divided into multiple stacked conductive layers, each layer serving as an independent connection level. This segmentation allows different connection configurations (star, delta, etc.) to be achieved by selectively connecting coils across different layers, simplifying the overall connection process while maintaining versatility.
Solution Approach 2:
The patent introduces a vertical stacking dimension to the traditional planar interconnection structure. By arranging conductive layers axially one above another, the device enables three-dimensional routing of electrical connections, reducing cable distances and allowing multiple connection configurations without increasing planar complexity.
2Adaptability or versatility
If multiple connection configurations are supported, then adaptability to different voltage and network conditions is improved, but the structural complexity of the interconnection device increases
Solution Approach 1:
Each conductive layer is designed with universal functionality to support multiple connection configurations. The layers contain both internal connection tabs for coil connections and external connection tabs for electrical equipment, allowing the same layered structure to accommodate star, delta, and other configurations through flexible tab connections.
Solution Approach 2:
Different regions of the conductive layers are assigned specific functions: internal connection tabs are positioned for coil connections while external connection tabs are positioned for electrical equipment connections. This local differentiation allows the unified layered structure to achieve multiple connection configurations through selective local connections.
3Ease of operation
If internal connection tabs are exposed for easy access, then connection ease is improved, but the reliability of the connection decreases due to fragility
Solution Approach 1:
The internal connection tabs are nested within the interconnection device structure, specifically housed inside the layered assembly. This nesting protects the fragile internal tabs from external mechanical damage while maintaining electrical accessibility through the layered design, which allows connections to be made without exposing the tabs to external stress.
Data Source
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AI summary
The invention relates to an interconnection element (24) for connecting the stator coils of a polyphase rotary electric machine (2), characterised by including a plurality of conductive layers stacked axially, including the same number of solid base layers (26, 28, 30), and additional layers (32, 34, 36), each formed by a plurality of ring portions, each one of said ring portions not covering the entire perimeter of the stator, each one of said conductive layers having internal connection tabs (40) for connecting the coils and external connection tabs (48, 50) for connecting to connected electrical devices (4, 20), the number of base layers and additional layers being equal to the number of phases of the machine to which the interconnection element is added.