Stator Armature Joint Structure for Reliable Segment Conductor Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional rotary electric machine stators face issues where the tip end portions of segment conductors may not be sufficiently joined due to variations in coil dimensions, leading to inadequate pressing force and potential curvature of the coils, especially when the joint thickness is smaller than other parts, resulting in incomplete bonding.
Innovation Solution
The armature design ensures that the joint portion thickness is equal to or greater than the thickness of other parts in the radial direction, allowing for sufficient pressing force and preventing curvature, while maintaining a secure joint surface area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional spheroidizing treatment is performed on elongated steel scraps, then the steel chips can be formed into spheroidal shape, but the production time is excessively long (over 10 hours) and the spheroidization is incomplete
Solution Approach 1:
The invention applies preliminary action by performing a pre-spheroidizing treatment before the main spheroidizing process. The steel scraps are subjected to a first spheroidizing treatment that achieves partial spheroidization, creating a more favorable initial state for the subsequent treatment. This preliminary action reduces the time required for complete spheroidization while improving the overall efficiency of the process.
Solution Approach 2:
The invention implements periodic action by dividing the spheroidizing process into multiple distinct stages: a first spheroidizing treatment stage and a second spheroidizing treatment stage. Each stage uses different processing parameters and durations, with the first stage performing partial spheroidization and the second stage completing the process. This periodic approach optimizes both time efficiency and spheroidization completeness.
2Productivity
If high-speed steel chips are used as raw material, then productivity is improved, but the chips become hardened and cannot be spheroidized by conventional methods
Solution Approach 1:
The invention applies parameter changes by modifying the spheroidizing treatment parameters specifically for hardened high-speed steel chips. The first spheroidizing treatment uses optimized parameters (temperature, time, atmosphere) to initially process the hardened chips, making them more receptive to further treatment. The second spheroidizing treatment then completes the process with adjusted parameters, enabling successful spheroidization of materials that were previously unsuitable.
Solution Approach 2:
The invention uses preliminary action by applying a first spheroidizing treatment to hardened high-speed steel chips before attempting complete spheroidization. This initial treatment softens or prepares the hardened structure, making the chips amenable to the second spheroidizing treatment. Without this preliminary action, the hardened chips would resist conventional spheroidizing methods entirely.
3Reliability
If spheroidal powder is produced through conventional methods, then the powder can be used for sintering, but the process requires excessive time and energy consumption
Solution Approach 1:
The invention implements periodic action by structuring the spheroidizing process into two distinct treatment stages with different energy inputs and durations. The first spheroidizing treatment performs partial spheroidization with optimized energy consumption, and the second treatment completes the process efficiently. This periodic structure reduces total energy consumption compared to conventional single-stage methods while maintaining sintering quality through controlled, staged processing.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
In this stator armature (100), a first leg portion (71) has a first surface side part (71b) that has a thickness in a radial direction smaller than a thickness of a first leg portion body portion (71d) in the radial direction, a second leg portion (81) has a second surface side part (81b) that has a thickness in the radial direction smaller than a thickness of a second leg portion body portion (81d) in the radial direction, and in the radial direction, a thickness of a joint portion (90) is equal to or more than a thickness of a part (E2) other than the joint portion (90).