Stator Coil-End Connection Structure for Secure Conductor Fixing
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Solution Overview
Problem
Existing rotary electric machines face challenges in securely fixing connection conductors at coil ends, leading to potential disconnection issues during operation.
Innovation Solution
A stator design incorporating a connection unit with an insertion member and a bridge member made of resin, which couples the coil end and the insertion member, ensuring reliable positioning and secure fixation of the connection conductor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If one or more connection conductors are fixed to the coil end, then electrical connection is provided, but secure fixing is difficult and disconnection may occur during operation
Solution Approach 1:
The patent introduces an insertion member as an intermediary component between the connection conductor and the coil end. This insertion member is inserted into the coil end and couples the connection conductor to the coil end, providing secure fixing while maintaining electrical connection. The insertion member acts as a mediator that solves the fixation problem without requiring complex external fastening structures.
Solution Approach 2:
The insertion member is inserted into the coil end, creating a nested structure where the insertion member is contained within the coil end structure. This nesting approach provides secure fixation by utilizing the existing coil end geometry, eliminating the need for additional external fixing mechanisms and reducing overall structural complexity.
2Reliability
If a resin member is used to couple the coil end and insertion member, then the insertion member is prevented from dropping off, but manufacturing complexity increases
Solution Approach 1:
The resin member is applied in advance to the insertion member or coil end before assembly, creating a pre-formed coupling structure. This preliminary action ensures that when the insertion member is inserted into the coil end, the resin member is already in position to provide immediate coupling and prevent dropping off, simplifying the assembly process while ensuring reliable fixation.
Solution Approach 2:
The resin member changes its physical parameters from a liquid or semi-liquid state during application to a solid state after curing. This parameter change allows the resin member to initially flow into the coupling interface between the insertion member and coil end, then harden to provide strong mechanical bonding, achieving reliable fixation while maintaining ease of manufacture through a simple curing process.
Data Source
AI summary
A connection unit is coupled to a coil end. The connection unit includes an insulator member. The insulator member includes a holder member and an insertion member. The insertion member is inserted into the coil end. A resin member includes a protective layer which protects a plurality of joint members. The resin member includes a bridge member which couples the insulator member and the joint member. The insertion member is a cylindrical shape. The insertion member is capable of accepting a plurality of joint members. The insertion member is capable of storing the resin member.