Stator Lead Wire Nesting for Vibration Isolation
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Solution Overview
Problem
The existing arrangement of lead wires in rotating electric machines for motor vehicles results in increased weight and reduced rigidity, leading to low natural frequencies that can cause resonance with vehicle engine vibrations, potentially resulting in joint failure due to excessive stress.
Innovation Solution
The stator design includes lead wires with joints arranged radially inside the coil end part, minimizing extending lengths and weights, and using different lengths and phases to set natural frequencies outside the range of vehicle vibrations, with optional elastic members and temperature-sensing elements for enhanced support and failure detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If lead wires are arranged to extend across the coil end part to the radially outside, then the lead wires can be connected to external circuits, but the extending lengths become large, increasing weight and reducing rigidity
Solution Approach 1:
The patent changes the spatial arrangement of lead wires from radial extension to axial arrangement within the coil end part. By positioning lead wires to extend in the axial direction rather than radially outward, the effective length is reduced while maintaining connection functionality. This dimensional reorientation solves the contradiction between connection ease and weight reduction.
Solution Approach 2:
The lead wires are nested within the coil end part structure rather than extending externally. The distal ends of lead wires are positioned within the axial space of the coil end part, utilizing the existing structural volume. This nesting approach reduces the external footprint and weight while preserving electrical connection capability.
2Ease of operation
If lead wires extend across the coil end part, then connections can be made, but the natural frequencies are lowered causing resonance with vehicle engine vibrations
Solution Approach 1:
By reorienting lead wire extension from radial to axial direction within the coil end part, the patent changes the vibrational characteristics and natural frequencies of the lead wires. This dimensional change ensures that the natural frequencies fall outside the vehicle engine vibration frequency range, preventing resonance and improving joint reliability.
Solution Approach 2:
The patent changes the physical parameters of the lead wire arrangement, specifically the extension direction and position within the coil end part. By adjusting these parameters, the natural frequencies of the lead wires are modified to avoid resonance with vehicle vibrations, thereby improving reliability without compromising connection ease.
3Ease of operation
If lead wires are arranged to hang over the coil end part, then connections can be established, but the rigidities are lowered and excessive stress is induced in joints
Solution Approach 1:
The lead wires are nested within the axial space of the coil end part rather than hanging over the radial exterior. This containment arrangement provides structural support from the coil end part itself, maintaining lead wire rigidity and preventing excessive stress concentration at connection joints while preserving electrical connectivity.
Solution Approach 2:
The patent modifies the spatial parameters of lead wire positioning by transitioning from radial hanging arrangement to axial nesting within the coil end part. This parameter change enhances the structural support for lead wires, maintaining rigidity and reducing stress on joints while keeping connections accessible.
Data Source
AI summary
A stator includes an annular stator core and a multi-phase stator coil. The stator core has slots arranged in a circumferential direction thereof. The stator coil is comprised of phase windings that are mounted on the stator core so as to be received in the slots of the stator core. The stator coil has an annular coil end part protruding axially outward from an axial end face of the stator core. The stator coil includes, at least, two lead wires and a joint. Each of the lead wires is connected with one of the phase windings of the stator coil and led out from a radially inner periphery of the coil end part. At the joint, distal ends of the lead wires are joined to each other. Adjoining portions of the lead wires, which adjoin each other, are arranged radially inside a radially-inner peripheral surface of the coil end part.