Wound Rotor Wire Routing for Robust Slipring Crimping
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Solution Overview
Problem
Poor routing and crimping of winding wire in wound rotors lead to incorrect positioning, residual stresses, and mechanical failures such as wire slippage, breakage, and hook opening due to centrifugal forces and vibrations, compromising the mechanical integrity and reliability of the connections.
Innovation Solution
A modified winding scheme where the wire is wound in ascending numerical order with specific angles and pins to facilitate contact with the shaft and slipring, ensuring optimal crimping and mechanical robustness, and the use of angular contact points to secure the wire connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the winding wire is routed through the slots and connected to the slipring by hooks, then electrical connection is achieved, but the wire positioning becomes incorrect and residual stresses occur
Solution Approach 1:
The patent introduces preliminary routing guides and positioning elements that are installed before the winding wire is crimped into the hooks. These guides pre-position the wire correctly along its path through the slots, ensuring accurate final positioning in the hooks and preventing residual stresses from incorrect routing.
Solution Approach 2:
The patent employs intermediary components such as routing guides, positioning pins, and tensioning elements that mediate between the winding wire and the final hook connection. These intermediaries ensure the wire follows the correct path and is positioned accurately before crimping, resolving the positioning precision issue while maintaining connection reliability.
2Ease of manufacture
If the wire is crimped to the hooks under tension, then electrical connection is established, but mechanical failures occur due to residual stresses and centrifugal forces
Solution Approach 1:
The patent incorporates cushioning elements and stress-absorbing features in the routing path before the wire reaches the hooks. These elements absorb and distribute the tension and residual stresses during crimping, preventing stress concentration that would lead to mechanical failures under centrifugal forces and vibrations.
Solution Approach 2:
The patent modifies the crimping parameters and wire routing geometry to optimize the connection. By changing the routing angle, tension distribution, and crimping force parameters, the patent achieves reliable electrical connection while minimizing residual stresses that would cause mechanical failure under operational loads.
3Device complexity
If the winding passage is simplified for easier manufacturing, then production complexity is reduced, but the wire mechanical integrity under centrifugal force deteriorates
Solution Approach 1:
The patent segments the winding passage into distinct functional zones: routing guide sections, tension distribution sections, and connection sections. Each segment is optimized for its specific function, allowing the overall system to achieve high mechanical integrity without excessive overall complexity. The segmentation enables standardized manufacturing while maintaining wire integrity under centrifugal force.
Data Source
AI summary
A wound rotor, such as a wound rotor for an electric machine, includes a shaft having a main axis. The shaft includes a manifold. The wound rotor also includes a winding wire and n poles wound and ordered with an ascending order number obtained by rotation about the main axis. The n wound poles can be distributed radially about the main axis. The n poles are wound with the wire in series in turn according to their ascending order numbers, the last pole, however, not being wound last.