Stator Terminal Crimp Layout for Compact Vibration-Resistant Armatures
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Solution Overview
Problem
Rotating electrical machines in vehicles face challenges in reducing their size in the axial direction while maintaining efficiency and reliability, particularly in the design of stator cores and terminal connections.
Innovation Solution
The design incorporates a stator core with teeth arranged circumferentially, insulators, and conductive coils with terminals made from electrically conductive materials, featuring crimp connections and press-fit protrusions to minimize size and enhance stability against mechanical vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the number of connectors is reduced to decrease device complexity, then the axial size is reduced, but the reliability of electrical connections may deteriorate
Solution Approach 1:
Multiple connectors are merged into a single integrated terminal structure. The terminal includes multiple crimps arranged circumferentially, each capable of connecting to coil ends, and multiple insulator retainers that secure multiple coils simultaneously. This consolidation reduces the total number of separate connector components while maintaining reliable electrical connections across all coil phases.
Solution Approach 2:
The terminal structure serves multiple functions within a single component: it provides electrical connection through crimps, mechanical support through the terminal body, insulation through integrated retainers, and structural anchoring to the stator core. This multi-functional design eliminates the need for separate connectors, insulators, and mounting components, thereby reducing overall device complexity while ensuring connection reliability.
2Length of moving object
If the axial size of the rotating electrical machine is reduced, then the space occupation is decreased, but the stability against mechanical vibrations may worsen
Solution Approach 1:
The terminal structure is nested within the stator core assembly, with insulator retainers secured to the stator core and crimps positioned between adjacent coils. This nested arrangement minimizes the axial protrusion of connection components while maintaining structural integrity and vibration resistance through integrated positioning.
Solution Approach 2:
The terminal components are arranged in the circumferential direction rather than extending axially. Multiple crimps are positioned around the circumference at different angular positions, allowing electrical connections to be made without increasing axial length. This dimensional reconfiguration maintains vibration stability while achieving compact axial size.
3Ease of manufacture
If the terminal structure is simplified to reduce device complexity, then manufacturing ease is improved, but the resistance to disconnection under mechanical stress may worsen
Solution Approach 1:
The terminal integrates multiple connection functions into a single molded structure, combining crimps, insulator retainers, and mounting features into one component. This consolidation simplifies manufacturing by reducing the number of assembly steps and components, while the integrated design ensures that all connection elements are pre-positioned and secured together, preventing disconnection under mechanical stress.
Solution Approach 2:
The terminal is constructed from electrically conductive material with integrated insulator retainers made from insulating material. This composite structure provides both electrical connection capability and mechanical strength in a single component, ensuring resistance to disconnection while simplifying the overall assembly process compared to separate metal and plastic components.
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 configuration allows for a reduction in the axial size of the rotating electrical machine while improving reliability and resistance to mechanical vibrations, ensuring efficient operation and reduced risk of disconnection.
Implementation Method 1
a crimp to which a coil end of the coils is secured
Implementation Method 2
an insulator retainer secured to the insulator
Data Source
AI summary
A stator includes a stator core, an insulator, and a plurality of coils. The stator core is equipped with teeth which are arranged away from each other in a circumferential direction of the stator. The insulator is secured to the stator core. The coils are made of windings of conductive wires around the teeth. The stator also includes terminals (i.e., first terminals and a second terminal). The terminals include insulator retainers (i.e., first insulator retainers and a second insulator retainer) and crimps. The insulator retainers are secured to the insulator. Each of the crimps is disposed between two of the coils which are arranged adjacent to each other in the circumferential direction. Ends of the coils (i.e., first ends and second ends) are secured to the crimps.