Stator Connection Terminal Melting Material Placement
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Solution Overview
Problem
Existing methods for connecting stator coils in rotating electric machines face issues with productivity due to brazing material thickness and deformation under severe operating conditions, particularly in connection terminals for automobiles.
Innovation Solution
A stator with a connection terminal featuring a pressure connection portion and a fastening portion, where a melting material is disposed in the fastening portion to enhance mechanical connection and reduce deformation, improving both productivity and aseismic capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If projections are formed on the copper plate to connect brazing material, then connection strength is improved, but the brazing material or projecting parts may get stuck when inserting the coil, reducing productivity
Solution Approach 1:
The invention extracts the brazing material from the pressure connection portion and relocates it to the fastening portion. This separation allows the pressure connection portion to have a smooth surface for easy coil insertion, while the fastening portion contains the brazing material for strong mechanical connection, thus resolving the contradiction between connection strength and productivity
Solution Approach 2:
The invention uses the fastening portion as an intermediary structure that contains the brazing material, which acts as a mediator between the connection terminal and the external system. This intermediary placement allows the brazing material to provide strong connection without interfering with the coil insertion process in the pressure connection portion
2Reliability
If brazing material is used to connect coil to connection terminal, then connection is achieved, but under severe operating conditions the basic material may deform at the fastening portion, reducing reliability
Solution Approach 1:
The invention applies local quality by placing the brazing material specifically in the fastening portion where it is needed for mechanical connection and seismic resistance, while keeping the pressure connection portion smooth for electrical connection. This localized placement ensures that the brazing material reinforces the fastening portion without interfering with the pressure connection area, improving reliability under severe conditions
Solution Approach 2:
The invention uses composite construction by combining the basic material (copper plate) with brazing material in a layered configuration. The brazing material is disposed on one surface of the basic material at the fastening portion, creating a composite structure that leverages the strengths of both materials: the basic material provides electrical conductivity and structural form, while the brazing material provides enhanced mechanical strength and deformation resistance
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
The solution provides a stator with high productivity and aseismic capacity, effectively addressing the challenges of material sticking and deformation in connection terminals, ensuring reliable operation under demanding conditions.
Implementation Method 1
a melting material is disposed in the fastening portion
Data Source
AI summary
Provided is a stator for a rotating electric machine equipped with a connection terminal having high manufacturability and vibration resistance; also provided is a rotating electric machine equipped with this stator. The stator, which is for a rotating electric machine equipped with a stator coil, is equipped with a connection terminal. The connection terminal has a crimping part to which stator coil input/output coil conductors are connected, and a fastening part which is mechanically connected to an external mechanism, with a melt material arranged on the fastening part. The input/output coil conductors are configured so as to be connected to the connection terminal, with the melt material provided on the crimping part therebetween.