Stepped Connection Member for Compact Rotating Electric Machine
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Solution Overview
Problem
Conventional rotating electric machines for hybrid cars face challenges in compact design due to restricted axis-direction length, necessitating wider bus bars that increase the machine's overall length, making it difficult to fit in narrow spaces between the engine and transmission.
Innovation Solution
A rotating electric machine design featuring a connection member with a stepped axis-direction end face, where different radial positions have varying axis-direction positions, allowing for a compact form factor without extending the axis-direction length, and incorporating a ring-shaped insulation holder with bus bars of varying thickness and width to match the conical housing shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bus bars are arranged with the same width at different radial positions, then manufacturing is simplified, but the axis-direction length must be increased to maintain adequate cross-sectional area for current handling
Solution Approach 1:
The connection member features a stepped configuration where the axis-direction position varies at different radial positions. Specifically, the outer peripheral portion is positioned closer to the stator than the inner peripheral portion, creating different local heights. This allows bus bars at different radial positions to have different effective lengths while maintaining uniform width, optimizing current handling without increasing overall axis-direction length
Solution Approach 2:
The invention transitions from a uniform cylindrical connection member to a stepped conical configuration by varying the axis-direction position across different radial positions. This dimensional variation creates a multi-level structure where the connection member's height changes in the axis-direction based on radial position, enabling compact design while maintaining electrical performance
2Volume of moving object
If the connection member outer diameter is reduced to fit the conical housing, then the machine fits in narrow spaces, but the bus bar cross-sectional area decreases
Solution Approach 1:
The stepped configuration creates different local heights at different radial positions, allowing the connection member to have a smaller outer diameter while providing sufficient effective length for bus bars at each radial position. The outer peripheral portion can be shorter to reduce overall diameter, while inner portions maintain adequate length for current handling
Solution Approach 2:
By varying the axis-direction position across radial positions, the invention creates a stepped conical shape that reduces the maximum outer diameter of the connection member. This dimensional variation allows the machine to fit in narrower housing spaces while maintaining adequate bus bar cross-sectional areas through optimized local heights
3Ease of manufacture
If the connection member has a uniform cylindrical shape, then manufacturing is easier, but the axis-direction length increases to accommodate adequate bus bar cross-sectional area
Solution Approach 1:
The connection member features a stepped configuration where the axis-direction position varies at different radial positions. Specifically, the outer peripheral portion is positioned closer to the stator than the inner peripheral portion, creating different local heights. This allows bus bars at different radial positions to have different effective lengths while maintaining uniform width, optimizing current handling without increasing overall axis-direction length
Solution Approach 2:
The invention transitions from a uniform cylindrical connection member to a stepped conical configuration by varying the axis-direction position across different radial positions. This dimensional variation creates a multi-level structure where the connection member's height changes in the axis-direction based on radial position, enabling compact design while maintaining electrical performance
Data Source
AI summary
A rotating electric machine is provided with a connection member, formed in the shape of a ring, that is disposed on at least one axis-direction end of a stator core and that mutually connects a plurality of coils; the axis-direction end face, at the stator-opposite side, of the connection member is formed in such a way that at a plurality of different positions in the radial direction of the connection member, the axis-direction positions of the connection member differ from one another.