Stator Interconnector with Welding Tabs for Electric Machine
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Solution Overview
Problem
The existing interconnectors for polyphase rotating electrical machines hinder the welding operations due to the close assembly of coil ends and legs, making it difficult for welding electrodes to access and connect the ends of the coils effectively.
Innovation Solution
The interconnector is designed with circular conductors that have tabs for welding the input and output ends of the coils, and L-shaped support feet to rest on the stator's yoke, allowing for better access and distribution of coil ends, enabling easier welding operations while maintaining the existing structure with reduced complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the interconnector uses a compact single-part design, then the device complexity is reduced, but the welding operations become difficult due to close assembly of coil ends and legs
Solution Approach 1:
The interconnector is divided into two separate parts: a first part with circular conductors for connecting coil input ends, and a second part with circular conductors for connecting coil output ends. These parts are positioned on opposite sides of the stator body, allowing welding electrodes to access the connection points without interference from other components, thus resolving the welding accessibility issue while maintaining structural simplicity through modular design.
2Volume of moving object
If the interconnector components are positioned close together, then the device size is reduced, but the welding electrodes cannot access the coil ends effectively
Solution Approach 1:
The interconnector parts are arranged in the axial dimension rather than being positioned close together in the radial plane. The first part is positioned at one axial end of the stator body while the second part is positioned at the opposite axial end, allowing welding electrodes to access connection points from opposite directions along the axial dimension, effectively resolving the accessibility problem without significantly increasing overall device volume.
3Ease of manufacture
If the interconnector uses a single-part design, then the manufacturing process is simplified, but the rotor cannot be mounted axially in both directions
Solution Approach 1:
The two parts of the interconnector are designed with asymmetric functionality: the first part is configured to connect input ends of coils with lugs extending in one axial direction, while the second part is configured to connect output ends of coils with lugs extending in the opposite axial direction. This asymmetric design enables the rotor to be mounted axially in either direction while maintaining proper electrical connections, providing mounting versatility without complicating the manufacturing process.
Data Source
Figure 1~2b
Figure 3~4
Figure 5~7
AI summary
The invention relates to an interconnector having circular conductors (31-34) for a stator of a polyphase rotary electric machine including a body (12) of a stator (11) having a winding provided with a plurality of coils (19) each having input (191) and output (192) ends, characterised in that said interconnector comprises a first portion (22a) including at least three circular conductors (32-34) having an annular shape stacked axially on top of one another and electrically isolated from one another, and a second portion (22b) including at least one electrically insulated circular conductor (31) having an annular shape, said first and second portions being intended for being installed on either side of the body (12) of the stator, also characterised in that the circular conductors (32-34) of the first portion (22a) and the circular conductors (31) of the second portion (22b) have, on the inner periphery thereof, tabs (36) projecting inwardly for welding the input ends (191) and the output ends (192) of the coils, respectively. According to the invention, a stator of a rotary electric machine is characterised in that it is provided with such an interconnector.