Stator Terminal Member Dual-Fixing for Vibration Reliability
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Solution Overview
Problem
The existing bonding structure of metal terminals and lead conductors in rotary electric machines, which relies on swaging and arc welding between bonding pieces, lacks sufficient fixing strength for vibrations, leading to unreliable connections in high-temperature and vibration-prone environments.
Innovation Solution
A stator design with a terminal member that includes both a winding-side connection portion and a leading-end-side connection portion, where the lead conductor is fixed using metal fusion bonding and mechanical coupling at separate locations, enhancing the connection reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the lead conductor and metal terminal are fixed by arc welding only at the location between bonding pieces, then the manufacturing process is simple, but the fixing strength for vibration is insufficient
Solution Approach 1:
The connection portion of the metal terminal is divided into two separate connection portions: a winding-side connection portion and a leading-end-side connection portion. This segmentation allows the lead conductor to be fixed at multiple locations, improving vibration resistance while maintaining manufacturing simplicity through modular construction
Solution Approach 2:
The fixing method transitions from a single-point arc welding approach to a multi-point fixation system that includes both arc welding and swaging operations at different locations. This dimensional expansion of the connection strategy enhances reliability without significantly complicating the manufacturing process
2Ease of manufacture
If soldering is used to bond the lead conductor and metal terminal, then the initial bonding is achieved, but thermal degradation occurs in high-temperature environments
Solution Approach 1:
The patent replaces the thermal bonding process (soldering) with mechanical bonding methods including swaging and arc welding. This substitution eliminates the thermal degradation issue inherent in soldering while maintaining ease of manufacture through established mechanical joining techniques
Solution Approach 2:
The bonding method parameters are changed from thermal (soldering temperature) to mechanical (swaging pressure, arc welding current). This parameter transformation allows the connection to withstand high-temperature environments without the thermal degradation that plagues soldered joints
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 dual-fixing approach increases the reliability of the connection between the lead conductor and the terminal member by dispersing stress from vibrations and minimizing variations in electrical characteristics due to heat-induced composition changes.
Implementation Method 1
a first step of fixing the lead conductor and the leading-end-side connection portion by metal fusion bonding
Implementation Method 2
a second step of fixing the lead conductor and the winding-side connection portion by coupling different from the metal fusion bonding, or by mechanical coupling
Data Source
AI summary
Provided is a rotor capable of improving the reliability of a connection between a lead conductor and a terminal member. A stator includes a winding wound around a stator core and having a lead conductor at an end thereof, and a terminal member having a connection portion to the lead conductor of the winding. The connection portion of the terminal member includes a winding-side connection portion that fixes the lead conductor, and a leading-end-side connection portion that fixes a portion closer to a leading end of the lead conductor than the winding-side connection portion.