Terminal Block Vibration Damping via Integrated Resin Member
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Solution Overview
Problem
The existing terminal block connection structures for rotary electric machines experience excessive stress at the joining portions between stator coils and power lines due to vibrations, which can reduce the durability of the connection.
Innovation Solution
A terminal block connection structure that integrates a resin member with the terminal metal fittings on the opposite side of the power lines, using fastening members to connect the power lines to the terminal block, which helps to absorb and reduce vibrations and improve workability during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal block connection structure is used to connect power lines to terminal blocks, then electrical connection is achieved, but excessive stress occurs at the joining portion between stator coil and power line due to vibration
Solution Approach 1:
A resin member is introduced as an intermediary between the power line and the terminal metal fitting. This resin member absorbs and dampens vibration energy, preventing excessive stress from being transmitted to the joining portion between the stator coil and power line, thereby improving connection durability while reducing stress concentration.
Solution Approach 2:
The connection structure uses a composite assembly consisting of the resin member integrated with the terminal metal fitting. The combination of resin (vibration-dampening material) and metal (conductive and structurally sound material) creates a composite component that simultaneously provides electrical connection, vibration absorption, and stress reduction.
2Reliability
If vibration damping measures are implemented to reduce stress at joining portions, then connection durability improves, but device complexity increases
Solution Approach 1:
The resin member is merged with the terminal metal fitting to form an integrated composite component. This merging approach combines the vibration-dampening function of the resin with the electrical connection function of the metal fitting into a single unified structure, achieving vibration damping without significantly increasing overall device 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
This configuration effectively reduces stress at the joining portions between the stator coils and power lines when vibrations occur, enhancing the durability of the connection and improving the assembly process by restraining vibrations and facilitating easier connection operations.
Implementation Method 1
the resin member relaxes the vibration. This makes it possible to reduce a stress to occur in a joining portion between the stator coil and the power line
Data Source
AI summary
A terminal block connection structure for a rotary electric machine includes: a plurality of power lines configured such that respective first end portions are joined to stator coils of a plurality of phases of the rotary electric machine; terminal metal fittings provided in respective second end portions of the plurality of power lines; a terminal block to which the terminal metal fittings are fixed by respective fastening members; and a resin member integrated with an end part of at least one of the terminal metal fittings relative on an opposite side to the power lines across its corresponding fastening member. The terminal block is configured such that a plurality of power-source lines is connected to the terminal block and the terminal metal fittings are fixed to the terminal block by the respective fastening members so that the plurality of power lines is connected to the plurality of power-source lines, respectively.