Stator Interconnection Layout for Compact Rod Conductor Welding
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Solution Overview
Problem
The existing methods for connecting segmental conductors in electric machine windings are cumbersome and inefficient, either requiring cumbersome assembly with separate interconnection pieces or resulting in a large structural height when directly welded, and fail to optimize installation space and electrical connection reliability.
Innovation Solution
A stator design featuring radially distributed rod conductors with grouped interconnection pieces, each forming interconnection planes along the axis of rotation, allowing for compact and simplified assembly with reduced material usage and improved cooling, using curved or z-shaped interconnection pieces that can be pre-positioned and connected via welding for secure electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate interconnection pieces are used to connect rod conductors, then electrical connection reliability is improved, but assembly complexity increases
Solution Approach 1:
The interconnection pieces are pre-assembled onto the rod conductors in a preliminary assembly step before final installation. This preliminary action allows for precise positioning and preparation of connection points, ensuring reliable electrical contact while simplifying the final assembly process by having components ready-to-install.
Solution Approach 2:
The patent introduces insulating discs as intermediary components that facilitate the connection process. These discs serve as carriers for interconnection pieces and provide insulation, enabling reliable electrical connection while simplifying assembly through a modular approach where components are pre-grouped on the discs.
2Device complexity
If rod conductors are directly welded without interconnection pieces, then assembly is simplified, but structural height increases
Solution Approach 1:
The patent arranges interconnection pieces in radially distributed groups at different axial positions, utilizing the radial and axial dimensions efficiently. This dimensional arrangement allows connections to be made without increasing overall structural height, as connections are distributed across multiple planes rather than requiring linear stacking.
Solution Approach 2:
The interconnection pieces are arranged in nested groups where multiple connection points are organized concentrically around the rotor axis. This nesting allows multiple conductors to be connected in a compact radial arrangement, reducing the axial height requirement while maintaining all necessary connections.
3Volume of stationary object
If interconnection pieces are arranged in groups at different axial positions, then installation space is reduced, but manufacturing complexity increases
Solution Approach 1:
The stator winding is divided into multiple segments or groups, with interconnection pieces arranged in corresponding groups at different axial positions. This segmentation allows for modular manufacturing where each axial group can be prepared independently, then assembled together, reducing overall installation space while managing manufacturing complexity through standardization of modular units.
Solution Approach 2:
The insulating discs serve multiple functions: they carry interconnection pieces, provide electrical insulation, and establish axial positioning. This multi-functionality reduces the number of separate components needed, simplifying manufacturing while achieving compact axial arrangement of interconnection groups.
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 enables a simplified, cost-effective, and reliable electrical connection of rod conductors, reducing installation space and transmission losses while maintaining efficiency, and allows for modular assembly and effective cooling of the stator.
Implementation Method 1
one interconnection piece each of a group of interconnection pieces is provided for an electrical connection of two rod conductors from different groups of rod conductors
Implementation Method 2
the segmental conductors are made to abut against each other by means of positioning tools and directly welded to each other
Data Source
AI summary
The invention relates to a stator for an electric machine, comprising a plurality of rod conductors and a plurality of interconnection pieces. The interconnection pieces each have a curved shape, in particular the shape of a C, extending in the radial direction and about the axis of rotation of the stator; in order to form respective interconnection planes along the axis of rotation, each group of interconnection pieces is arranged in the region of at least one short end of the rod conductors of the associated group of rod conductors that are to be electrically connected. The invention further relates to a connection component and an electric machine.