Stator Lead Wire Connection Structure for Heat Release and Vibration Control
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Solution Overview
Problem
Rotary electric machines face challenges in heat release and vibration resistance, with existing stators not adequately addressing these issues for efficient operation.
Innovation Solution
The stator design incorporates a plate-shaped connection member thermally coupled to power terminals, providing a stable thermal path through inner and outer lead wires, and a bridge member for enhanced heat transfer and vibration suppression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional stator design is used, then结构简单 (structure is simple), but heat release is insufficient
Solution Approach 1:
The connection member is divided into multiple functional segments: inner lead wire, outer lead wire, plate-shaped member, and bridge member. Each segment performs a specific function in the thermal conduction path, allowing the system to achieve effective heat release while maintaining manageable structural complexity through modular design.
Solution Approach 2:
The plate-shaped member and bridge member act as thermal intermediaries between the coil end and the power terminal. These intermediary components create efficient thermal coupling paths, enabling heat to be conducted from the coil end through the lead wires and connection members to the power terminal, thereby improving heat release without requiring fundamental changes to the stator structure.
2Reliability
If conventional connection method is used, then manufacturing is simple, but vibration resistance is poor
Solution Approach 1:
The connection member merges multiple functions into a single integrated component: electrical connection, mechanical support, and thermal conduction. By combining the inner lead wire, outer lead wire, plate-shaped member, and bridge member into a unified connection structure, the design achieves improved vibration resistance while avoiding the need for multiple separate components, thus managing overall structural complexity.
Solution Approach 2:
The connection structure employs composite design with different materials optimized for specific functions: conductive materials for electrical connection, thermally conductive materials for heat dissipation, and mechanically robust materials for vibration resistance. This composite approach enables the connection member to simultaneously satisfy multiple performance requirements without excessive structural complexity.
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 achieves improved heat conduction and vibration suppression, leading to a rotary electric machine with enhanced heat release and operational stability.
Implementation Method 1
the connection member provides a thermal path which provides good heat conduction between the inner lead wire and the power terminal
Data Source
AI summary
A rotary electric machine includes a rotor and a stator. The stator has a coil end. The coil end has a plurality of lead wires. The plurality of lead wires have an inner lead wire with respect to the radial direction RD and an outer lead wire outside the inner lead wire with respect to the radial direction RD. The rotary electric machine includes a plurality of connection members. The inner lead wire and the outer lead wire are electrically and mechanically connected to the plurality of connection members. The plurality of connection members provide a heat transfer path from the inner lead wire. The inner lead wire and the outer lead wire demonstrate different vibration characteristics.