Wavy Rotary Machine Connection Layout for Compact Phase Control
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Solution Overview
Problem
Current electrical connection systems for rotating electrical machines, such as those in hybrid vehicle alternator-starters, face challenges in minimizing bulk, allowing direct phase control, and preventing overheating, while maintaining efficient current transfer.
Innovation Solution
An electrical connection device with internal and external connection members featuring a wavy shape, allowing connectors to be placed in hollows, reducing radial and axial bulk, and enabling efficient heat dissipation, while maintaining phase control capabilities through stacked and offset connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If connections are arranged on both outer and inner peripheries of the system, then the size and electrical proximity risk are reduced, but the surface area of the ring in the radial plane is reduced, leading to increased resistance and heat dissipation problems
Solution Approach 1:
The patent transitions from a two-dimensional planar arrangement to a three-dimensional wavy configuration. The trace forms peaks and hollows in the radial plane, allowing connectors to be positioned in hollows at different radial levels. This vertical dimensionality enables both reduced footprint and maintained surface area for heat dissipation.
Solution Approach 2:
The wavy trace structure creates nested hollows within the radial profile. Connectors are nested within these hollows, allowing multiple connectors to be arranged compactly without reducing the overall radial surface area. The hollows act as nested spaces that accommodate connectors while preserving the external surface for heat dissipation.
2Adaptability or versatility
If rigid electrical connection systems with multiple conductive rings are used, then phase control is enabled, but the system complexity and footprint increase significantly
Solution Approach 1:
The connection system is segmented into multiple connection members, each with a simplified wavy trace structure. Instead of multiple complex stacked rings, each connection member independently provides phase control capability through its wavy trace with connectors in hollows. This segmentation reduces overall system complexity while maintaining versatility.
Solution Approach 2:
Each connection member with the wavy trace structure serves multiple functions: it provides electrical connection, enables phase control, and facilitates heat dissipation through its radial surface. This multi-functionality reduces the need for separate specialized components, thereby reducing system complexity.
3Area of stationary object
If the ring surface area in the radial plane is reduced to accommodate connectors on both peripheries, then the footprint is minimized, but the resistance increases and current supply capability is reduced
Solution Approach 1:
The trace is configured with peaks and hollows in the radial plane, creating a three-dimensional wavy structure. This allows the trace to maintain a large radial surface area for low resistance and effective heat dissipation, while the hollows provide vertical space for connector placement. The dimensional transition enables both compact footprint and low resistance.
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
One aspect of the invention relates to an electrical connection device (300) comprising: · an internal connection member surrounding an axis X having a plot (101), and a plurality of connectors (103); · a first external connection member surrounding the axis X and being stacked axially with the internal connection member, comprising a plot (101), and a plurality of connectors (103); the device being characterized in that each plot (101) has a wavy shape forming troughs comprising internal troughs situated facing the axis X and external troughs situated on an external periphery, each connector (103) of the internal connection member being connected in an internal trough of the plot of the internal connection member and each connector (103) of the first external connection member being electrically connected in an external trough of the plot of the first external connection member.