Outer Rotor Generator Stator Winding Guide Protrusion
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Solution Overview
Problem
Existing stator structures for outer rotor multipolar generators face issues with winding slack and bending stress, as well as complexity in winding operations and vibration resistance, particularly due to inadequate connection methods and increased winding length.
Innovation Solution
A stator structure featuring an annular coupler with a guide protrusion guiding the winding end inward and a connecting terminal with a pressing portion that protrudes radially, allowing the winding to be bent at a right angle after fusing, reducing bending stress and eliminating the need for pre-tensioning, while facilitating automation and vibration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the winding end is simply inserted through the connecting terminal without pre-tensioning, then the operation is simplified, but slack remains in the winding after fusing processing
Solution Approach 1:
The guide protrusion is pre-configured on the coupler to automatically guide and tension the winding end as it is inserted through the connecting terminal. This preliminary action removes slack during the insertion process itself, eliminating the need for separate pre-tensioning operations while ensuring reliable connection after fusing.
2Reliability
If the connecting terminal is bent after fusing processing, then vibration resistance is improved, but bending stress is applied to the fused portion
Solution Approach 1:
The guide protrusion performs the tensioning action preliminarily during winding insertion, before fusing processing. This ensures the winding is already taut when fused, so subsequent bending of the connecting terminal after fusing does not create additional bending stress at the fused portion, maintaining both vibration resistance and fused joint strength.
Solution Approach 2:
Instead of bending the connecting terminal before fusing (which would create bending stress at the fused portion), the invention inverts the sequence: the winding is tensioned first via the guide protrusion, then fused in its tensioned state, and only after fusing is the connecting terminal bent. This inversion eliminates bending stress at the fused portion while still achieving vibration resistance.
3Reliability
If the winding length is increased to prevent slack, then slack is avoided, but the likelihood of causing new slack increases and winding operation becomes complicated
Solution Approach 1:
The guide protrusion acts as an intermediary mechanism between the winding end and the connecting terminal. Instead of increasing winding length to prevent slack, the guide protrusion actively manages the winding path and applies tension during insertion, effectively preventing slack without requiring excessive winding length or complicated winding patterns.
4Extent of automation
If the pressing portion protrudes inward in the radial direction of the coupler, then automation of fusing processing is facilitated, but the structure becomes more complex
Solution Approach 1:
The guide protrusion serves multiple functions: it guides the winding end during insertion, tensions the winding to remove slack, and positions the winding correctly for fusing. By integrating these multiple functions into a single structural element, the coupler achieves automation-friendly geometry without proportionally increasing overall 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
The solution enhances the reliability of the connection, reduces the risk of disconnection, simplifies the fusing process, improves vibration resistance, and streamlines assembly operations by reducing slack and bending stress, while allowing for separate assembly and fusing processes.
Implementation Method 1
a fusing (thermal caulking) technique by application of electric power and pressure is used as a method for connecting an end of an armature winding to a connecting terminal
Data Source
AI summary
In a stator structure 1 of an outer rotor generator, a pressing portion 33 provided on a first portion 31 of a connecting terminal 30 is configured to protrude inward in the radial direction of an annular coupler 20 when the connecting terminal 30 is attached to the coupler 20. The coupler 20 is formed with a circular cylindrical guide protrusion 23, and an outlet of a stator winding 5 having wound on a salient pole 10b is configured to be guided by the guide protrusion 23, bent inward in the radial direction and reach the pressing portion 33. After fusing processing, the first portion 31 on which the pressing portion 33 is provided is bent at a right angle toward a side opposed to a side with which the stator winding 5 is connected, and then a distal end thereof is locked at a lock portion 26.