Rotary Electric Machine Stator Axial Joint Design
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Solution Overview
Problem
Conventional rotary electric machines face productivity issues due to complex welding processes and increased coil end height caused by the radial stacking of conductor wire joints, which complicates clamping and requires longer connecting conductor lengths.
Innovation Solution
A rotary electric machine stator design featuring jointless, continuous conductor wires with insulating coatings, where the conductor terminals extend axially and are connected using connecting conductors with parallel contacting portions, allowing for easier clamping from the circumference and reducing the need to avoid the tips, thus simplifying the welding process and reducing coil end height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tip portions of conductor wires and connecting portions of connecting conductors are stacked in a radial direction, then the joint portions can be formed, but welding work space is limited making the welding process complicated and reducing productivity
Solution Approach 1:
The patent changes the stacking direction from radial to axial. The tip portions of conductor wires and connecting portions of connecting conductors are stacked in the axial direction, allowing clamping tools to approach from the axial direction rather than radially. This dimensional change provides sufficient welding work space and simplifies the welding process while maintaining reliable joint formation.
2Ease of manufacture
If clamping tool is used to clamp joint portions, then welding can be performed, but the length of connecting portions must be increased to ensure welding work space, increasing coil end height
Solution Approach 1:
The patent changes the stacking direction from radial to axial, which allows clamping tools to access the joint portions from the axial direction with sufficient work space. This eliminates the need to increase the length of connecting portions, thereby maintaining compact coil end height while ensuring welding feasibility.
3Ease of operation
If connecting portions are clamped to avoid vicinity of tips, then welding work space is ensured, but the length of connecting portions is increased
Solution Approach 1:
The patent changes the stacking direction from radial to axial, allowing clamping tools to approach from the axial direction. This enables the clamping operation to be performed without avoiding the vicinity of tips, as the axial approach provides sufficient clearance. Consequently, the connecting portions can be kept short while maintaining ease of welding operation.
4Reliability
If radial stacking is used for joint portions, then connecting can be achieved, but clamping tool insertion becomes complex requiring oblique insertion from above
Solution Approach 1:
The patent changes the stacking direction from radial to axial. This allows clamping tools to be inserted simply from the axial direction without requiring oblique insertion from above. The axial stacking arrangement provides direct access for clamping tools, significantly reducing insertion complexity while maintaining reliable connections.
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 enhances productivity by simplifying the welding process and reducing coil end height by allowing clamping from the sides, eliminating the need for longer connecting conductors and improving insulation reliability.
Implementation Method 1
a jointless, continuous conductor wire on which an insulating coating is coated
Implementation Method 2
connecting the tip portion of the first conductor terminal and the tip portion of the second conductor terminal that is subject to connection therewith using a connecting conductor
Data Source
AI summary
A plurality of coil groups are each configured by connecting a tip portion of a first conductor terminal and a tip portion of a second conductor terminal that is subject to connection therewith using a connecting conductor, and the connecting conductors include: a pair of connecting portions that are respectively disposed so as to contact the tip portion of the first conductor terminal and the tip portion of the second conductor terminal that is subject to connection therewith in a circumferential direction of the tip portions so as to be parallel to the tip portions, and that are joined together with the tip portions; and a linking portion that links the pair of connecting portions.