Stator Neutral Point Conductor Bending Design
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Solution Overview
Problem
The manufacturing process of neutral point connection conductors for three-phase coils in rotary electric machines is complex due to the requirement of press-forming flat plate-like metal members into annular shapes, as seen in existing technologies.
Innovation Solution
A stator design that employs a neutral point connection conductor formed by bending a single linear conductor with overlapping and bent portions, simplifying the manufacturing process and improving joinability by ensuring sufficient overlap and minimizing interference with the coils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a flat plate-like metal member is press-formed into an annular shape to form the neutral point connection conductor, then the conductor can connect three-phase coils, but the manufacturing process becomes complex
Solution Approach 1:
Instead of forming a complex annular shape from a flat plate through press-forming, the invention inverts the approach by using a linear conductor that is simply bent into the required configuration. This inversion of the manufacturing sequence transforms a complex forming process into a simple bending process, resolving the contradiction between ease of manufacture and shape complexity
Solution Approach 2:
The neutral point connection conductor is segmented into distinct functional portions: end portions for connecting to phase coils and an overlapping portion for connection. This segmentation allows each portion to be optimized independently while maintaining overall simplicity in the manufacturing process through linear conductor bending
2Ease of manufacture
If the overlapping portion of the neutral point connection conductor is joined to the coil at the bent portion, then connection is achieved, but joinability decreases
Solution Approach 1:
The linear conductor is pre-bent into the required configuration with the overlapping portion positioned before the actual connection to the coil. This preliminary action ensures that the straight portions of the conductor are used for joining, avoiding the reduced joinability that would occur if bending and joining were performed simultaneously or in reverse sequence
Data Source
AI summary
A stator for a rotary electric machine includes a stator core, three-phase coils, and a neutral point connection conductor. The three-phase coils are wound around the stator core. The neutral point connection conductor is connected to each of the three-phase coils. The neutral point connection conductor includes a linear conductor that is bent. The linear conductor includes two end portions and an overlapping portion in which the conductor is folded back and doubled up. One of the two end portions is connected to one-phase coil of the three-phase coils. The other of the two end portions is connected to another-phase coil of the three-phase coils. The overlapping portion is connected to the remaining-phase coil of the three-phase coils.