Welded High-Current Stator Connections for Low-Impedance Inverter Links
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Solution Overview
Problem
Existing high-current connections in dynamoelectric machines suffer from significant losses and require complex, space-consuming structures due to high voltage levels, necessitating insulation and traditional connections like crimp sleeves or soldering, which are cumbersome and inefficient.
Innovation Solution
A rotary dynamoelectric machine with a stator and rotor separated by an air gap, utilizing a magnetically conductive element with bar-shaped conductors connected via a butt joint welded connection and connecting elements, allowing direct electrical contact with inverter modules, eliminating the need for traditional connections and reducing impedance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional crimp sleeves or solder connections are used for high-current connections, then electrical contact is established, but significant losses occur and the structure becomes complex and space-consuming
Solution Approach 1:
The patent extracts and eliminates the intermediate connection elements (crimp sleeves, solder joints) from the electrical connection path. By using direct butt joint welded connections between bar-shaped conductors and connecting elements, the complex multi-component connection structure is replaced with a simple direct weld, reducing both electrical losses and structural complexity.
Solution Approach 2:
The patent merges the functions of multiple separate connection components into a single integrated welded joint. The connecting element directly joins the bar-shaped conductor to the terminal box or inverter module output, combining what were previously separate crimping, insulation, and connection functions into one seamless welded connection, thereby reducing losses and simplifying the structure.
2Productivity
If insulation and traditional connection techniques are used for high voltage transmission, then electrical contact is established, but the structure becomes cumbersome and inefficient
Solution Approach 1:
The patent replaces mechanical connection systems (crimping mechanisms, soldering processes, insulation materials) with a thermal welding process. The butt joint welded connection uses heat and pressure to create a metallurgical bond directly between conductors, eliminating the need for mechanical fasteners, adhesives, or insulation layers, thereby improving transmission efficiency and reducing structural complexity.
3Loss of energy
If bar-shaped conductors are directly connected to inverter modules using welded connections, then current transmission losses are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent introduces a connecting element as an intermediary component that facilitates the welded connection between the bar-shaped conductor and the inverter module output. This connecting element serves as a mediator that absorbs and compensates for dimensional tolerances and alignment variations, enabling precise welded connections without requiring extremely tight manufacturing tolerances on the conductors themselves.
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 approach enables efficient, compact, and robust high-current transmission with reduced losses, facilitating a more compact design and improved mechanical strength at the connection points, enhancing the efficiency and robustness of the dynamoelectric machine.
Implementation Method 1
a first end of a bar-shaped conductor is electrically contacted with at least one inverter module by means of a special welding method, in particular the contacting is undertaken using a butt joint welded connection
Data Source
AI summary
A rotary dynamoelectric machine includes a stator with a winding system arranged in a magnetically conductive element and including bar-shaped conductors arranged in grooves of the magnetically conductive element. Each conductor protrudes with a first end from a groove on an end face side of the magnetically conductive element. A connecting element connects to the first end of the conductor, and a contact element with a stud establishes an electrically low-impedance contact between the first end of the conductor and the connecting element to an inverter module, or a contact stud is designed for extension via a female/male contact to a further contact stud for contacting the connecting element so as to enable a connection of a plurality of inverter modules axially behind one another to the connecting element. A short circuit ring combines a second end of the conductors on another end face side of the magnetically conductive element.