Stator Lead Wire Configuration for Vibration Resistance
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Solution Overview
Problem
Stators for rotating electric machines face reduced vibration resistance and increased manufacturing costs due to the complexity of lead portion arrangements and the need for increased adhesive use, especially in vehicles subjected to severe vibration, which also compromises environmental resistance.
Innovation Solution
The stator design includes an annular stator core with slots for windings, where lead wires are configured with radially-extending and circumferentially-extending parts to enhance vibration resistance, and the use of electric conductor segments with specific cross-sectional shapes and connections to improve structural integrity and reduce adhesive requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the amount of adhesive is increased to fix the lead portions to the coil end part, then the vibration resistance is improved, but the manufacturing cost increases
Solution Approach 1:
The lead portions are pre-formed with bent shapes (radially-extending part and circumferentially-extending part) before assembly. This preliminary shaping allows the lead wires to mechanically interlock with the coil end part, reducing the reliance on adhesive and thereby reducing adhesive consumption and manufacturing cost while maintaining vibration resistance.
Solution Approach 2:
The lead wires utilize their own flexibility and shape to achieve self-fixing to the coil end part through the bent configuration. The radially-extending and circumferentially-extending parts create a mechanical interlocking structure that secures the lead portions without requiring excessive adhesive, allowing the component to serve its own fixation needs.
2Strength
If the number of spots where lead portions are fixed is increased due to complicated arrangement, then the structural integrity is improved, but the amount of adhesive used increases and manufacturing cost increases
Solution Approach 1:
The lead portions are pre-shaped with specific bent configurations (radially-extending part and circumferentially-extending part) before assembly. This preliminary action creates a mechanical interlocking structure that provides structural integrity through the lead wire's own geometry, reducing the need for multiple adhesive application spots and thereby reducing adhesive consumption and manufacturing cost.
3Reliability
If the number of spots where lead portions are fixed is increased, then the vibration resistance is improved, but the gap between stator coil and frame is reduced and environmental resistance is lowered
Solution Approach 1:
The lead portions are pre-formed with bent shapes (radially-extending part and circumferentially-extending part) that create mechanical interlocking with the coil end part. This preliminary shaping provides vibration resistance through the lead wire's own geometry, reducing the need for multiple fixation spots that would otherwise reduce the gap between the stator coil and frame, thereby maintaining environmental resistance.
4Strength
If threads are used to bind lead portions to the coil end part, then the fixation strength is improved, but scratches are formed on the lead portions and electrical insulation is compromised
Solution Approach 1:
A small amount of adhesive is used as an intermediary substance to bond the pre-shaped lead portions to the coil end part. This adhesive intermediary provides fixation strength without requiring mechanical threading that would scratch the lead portions and compromise electrical insulation, while the pre-shaped bent configuration of the lead wires provides additional mechanical interlocking.
Data Source
AI summary
A stator includes an annular stator core, a stator coil and a plurality of lead wires. The stator coil is comprised of windings mounted on the stator core and has a coil end part protruding from an axial end face of the stator core. Each of the lead wires is made up of a corresponding one of end portions of the windings of the stator coil. The lead wires include, at least, a first lead wire and a second lead wire. The first lead wire has a radially-extending part that adjoins the coil end part of the stator coil and extends in a radial direction of the stator core. The second lead wire has a circumferentially-extending part that adjoins and intersects the radially-extending part of the first lead wire and is located on the opposite side of the radially-extending part to the coil end part of the stator coil.