Abstract
An embodiment of the present disclosure may further provide an armature comprising: an iron core; a plurality of patch cords, each of the plurality of patch cords being disposed in a notch on the iron core independently; and at least one end module, wherein: each of the at least one end module includes a plurality of circuits; and the at least one end module is mounted to an end portion of the iron core along an axial direction such that the plurality of patch cords electrically connect to each other individually through a corresponding circuit of the plurality of circuit to form a winding. The present disclosure also provides at least one end module for an armature and a method for assembling an armature.
Claims
1. An armature, comprising: an iron core; a plurality of patch cords, each of the plurality of patch cords being disposed in a notch on the iron core independently; and at least one end module, wherein: each of the at least one end module includes a plurality of circuits, and the at least one end module is mounted to an end portion of the iron core along an axial direction such that the plurality of patch cords electrically connect to each other individually through a corresponding circuit of the plurality of circuit to form a winding.
2. The armature of claim 1, wherein the at least one end module has an integrated structure, and the at least one end module is flat in shape.
3. (canceled)
4. The armature of claim 1, wherein the at least one end module includes a plurality of bonding pads, each of which corresponds to one patch cord of the plurality patch cord that electrically connects to the corresponding circuit through a corresponding bonding pad of the plurality of bonding pads.
5. The armature of claim 4, wherein the corresponding bonding pad is electrically connected to the one patch cord through welding.
6. The armature of claim 4, wherein: the corresponding bonding pad includes a welded end and a circuit end; the welded end protrudes above a surface of the at least one end module, and electrically connects to the corresponding patch cord through welding; and the circuit end is located inside the at least one end module and in electrical connection with the corresponding circuit.
7. The armature of claim 1, wherein each of the at least one end module further includes a thermal conductor layer, which is close to the iron core when the at least one end module is mounted to the iron core.
8. The armature of claim 1, wherein the each of the at least one end module includes a plurality of openings, and each of the plurality of patch cords passes through a corresponding opening of the plurality of openings.
9. The armature of claim 1, wherein each of the plurality of patch cords is substantially a straight strip.
10. The armature of claim 9, wherein: the at least one end module includes a first end module and a second end module; the first end module and the second end module are mounted on two end portions along the axial direction of the iron core, respectively.
11. The armature of claim 1, wherein each of the plurality of patch cords has a substantial U-shape including two straight sections and one curved section, wherein the two straight sections are disposed inside the corresponding notches of the notch, and the curved section is located outside the notch.
12. The armature of claim 11, wherein the at least one end module includes one end module mounted on the end along the axial direction of the iron core.
13. An end module for an armature, the armature comprising: an iron core; and a plurality of patch cords, each of the plurality of patch cords being disposed in a notch of the iron core independently; wherein: each of the at least one end module includes a plurality of circuits; and is mounted on an end portion along axial direction of the iron core such that the plurality of patch cords are in electrical connection with each other individually through a corresponding circuit of the plurality of circuits to form a winding.
14. The end module of claim 13, wherein the at least one end module has an integral structure, and the at least one end module is flat in shape.
15. (canceled)
16. The end module of claim 13, wherein the at least end module includes a plurality of bonding pads, each of which corresponds to one patch cord of the plurality of patch cords that electrically connects to the corresponding circuit through a corresponding bonding pad of the plurality of bonding pads.
17. (canceled)
18. (canceled)
19. The end module of claim 13, wherein each of the at least one end module further includes a thermal conductor layer, which is close to the iron core when the at least one end module is mounted to the iron core.
20. The end module of claim 13, wherein each of the at least one end module includes a plurality of openings, and each of the plurality of patch cords passes through a corresponding opening of the plurality of openings.
21. A method for assembling an armature, comprising: providing an iron core and a plurality of patch cords; each of the plurality of patch cords being disposed in a notch of the iron core independently; providing at least one end module, wherein the at least one end module includes a plurality of circuits; and the at least one end module is mounted to an end portion of the iron core along axial direction such that the plurality of patch cords electrically connect to each other individually through a corresponding circuit of the plurality of circuits to form a winding.
22. The method of claim 21, wherein the at least one end module is mounted to an end portion of the iron core comprising: passing each of the plurality of patch cords through a corresponding opening of the at least one end module; and soldering the each of the plurality of patch cords to a corresponding bonding pad of the at least one end module to form an electrical connection, wherein the corresponding bonding pad forms an electrical connection with the corresponding circuit within the at least one end module.
23. The method of claim 21, wherein: each of the plurality of patch cords is substantially a straight strip; the at least one end module includes a first end module and a second end module; and the first end module and the second end module are mounted on two end portions along axial directions of the iron core, respectively.
24. The method of claim 21, wherein each of the plurality of patch cords has a substantially U-shape including two straight sections and one curved section, wherein the two straight sections are placed inside corresponding notches of the iron core; the curved section is placed outside the notch; and the at least one end module is mounted on the end portion along the axial direction of the iron core.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] Detailed descriptions are given below in combination with the drawings in the present disclosure.
[0031] FIG. 1 and FIG. 2 show perspective views of an armature according to an embodiment of the present disclosure, wherein the armature shown in FIG. 1 is in an assembled state, and FIG. 2 is an exploded view of the armature.
[0032] FIG. 3 and FIG. 4 respectively shows an iron core of the armature as shown in FIG. 1, wherein FIG. 3 is a perspective view of the iron core, and FIG. 4 is a top view of the iron core.
[0033] FIG. 5 and FIG. 6 are schematic views showing an arrangement of a patch cord in the armature as shown in FIG. 1, wherein FIG. 5 is a perspective view of the patch cord arrangement, and FIG. 6 is a top view thereof.
[0034] FIG. 7 and FIG. 8 are schematic views showing an arrangement of an insulating paper in the armature as shown in FIG. 1, wherein FIG. 5 is a perspective view of the insulating paper arrangement, and FIG. 8 is a top view thereof.
[0035] FIG. 9 and FIG. 10 are schematic views of an end module of the armature as shown in FIG. 1, wherein FIG. 9 is a perspective view of the end module, and FIG. 10 is a top view of the end module.
[0036] FIG. 11 is an enlarged schematic view showing an axial sectional view of the end module as shown in FIG. 9, wherein the end module is partially omitted to clearly and concisely show the internal configuration of the end module, and the electrical connection relationship between a patch cord and a corresponding circuit within the end module is especially shown.
[0037] FIG. 12 shows a radial cross-sectional view of the end module as shown in FIG. 9.
[0038] FIG. 13a-13d show various exemplary patch cords that may be used for the armature as shown in FIG. 1.
[0039] FIG. 14a-14e show exemplary methods for assembling the armature as shown in FIG. 1.
[0040] FIG. 15 shows an armature according to another embodiment of the present disclosure.
[0041] FIG. 16 shows an armature according to yet another embodiment of the present disclosure.
DETAILED DESCRIPTION
[0042] FIG. 1 and FIG. 2 show perspective views of an armature 60 according to one embodiment of the present disclosure. FIG. 1 shows the armature 60 in an assembled view, and FIG. 2 is an exploded view of the armature 60. As shown in the FIGs, the armature 60 may include an iron core 10, and each of two end portions of the iron core 10 along the axial direction includes an end module 30 (30). The armature 60 shown in FIG. 1 may also include a plurality of patch cords 20. The plurality of patch cords 20 may be arranged in notches 11 (as shown in FIG. 3) of the iron core 10, and respectively pass through the end modules 30 (30) at both ends. These patch cords 20 may form a complete winding by an electrical connection between the corresponding circuits of the plurality of circuits in the end module. Each winding may include two patch cords protruding from the end module, and the patch cords may be used as outgoing lines of each winding. As shown in the FIGs, the armature may have six outgoing lines, that is, the illustrated armature has three windings. Each winding may be a coil formed by multiple patch cords electrically connecting with each other through the corresponding circuit in two end modules. Each winding may have two outgoing lines. As shown in FIG. 2, each patch cord 20 may be not directly in contact with the iron core in the notch of the iron core 10. Each patch cord 20 is covered by an insulating paper 40, which may be further explained below.
[0043] Referring further to FIG. 3 and FIG. 4, which illustrate the iron core 10 of the armature as shown in FIG. 1. FIG. 3 is a perspective view of the iron core 10 and FIG. 4 is a top view of the iron core 10. The iron core 10 may be laminated by a plurality of silicon steel sheets, and each silicon steel sheet may be insulated from each other. Each silicon steel sheet is provided with a plurality of notches 11 for arranging the patch cords 20. Except for silicon steel sheet, the material of the iron core 10 may include pure iron, mild steel, silicon steel, iron alloy, iron alloy, amorphous alloy, and microcrystalline alloy, etc. Those skilled in the art may understand that different materials may lead to different properties of the iron core 10, and thus the armature may be fabricated by selecting a suitable material depending on a specific use environment.
[0044] Referring further to FIG. 5 and FIG. 6, which are schematic views showing the arrangement of the patch cords 20 in the armature as shown in FIG. 1. FIG. 5 is a perspective view of the arrangement of the patch cords 20, and FIG. 6 is a top view thereof. As shown in the FIGs, the plurality of patch cords 20 may be arranged substantially coaxially and have a substantially uniform spacing between any two of the plurality of patch cords 20. However, those skilled in the art may understand that the arrangement of these patch cords may also have other different configurations.
[0045] Referring further to FIG. 7 and FIG. 8, which are schematic views showing the arrangement of the insulating paper 40 in the armature as shown in FIG. 1, wherein FIG. 5 is a perspective view of an arrangement of the insulating paper 40, and FIG. 6 is a top view thereof. As mentioned earlier, each patch cord is placed in an iron core's notch. However, to ensure insulation between the patch cords and insulation between the patch cords and the iron core, each patch cord is wrapped by the insulating paper 40. In general, the insulating paper 40 is folded from a single sheet with an insulating property, and may have substantially the same cross-section as the patch cords 20. Materials of the insulating paper 40 and methods for folding the insulating paper 40 are well-known in the art. As shown in the FIGs, these folded insulating papers 40 may be arranged substantially coaxially and have a substantially uniform spacing between any two of the insulating papers 40, which is consistent with the arrangement of patch cords 20 in the iron core 10. Similarly, those skilled in the art may understand that the arrangement of these insulating papers 40 may also have other different configurations corresponding to the plurality of patch cords 20.
[0046] Referring further to FIG. 9 and FIG. 10, which are schematic views of the end module 30 of the armature 60 as shown in FIG. 1. FIG. 9 is a perspective view of the end module 30, and FIG. 10 is a top view of the end module 30. The end module 30 and the end module 30 shown in FIG. 1 may be different in specific circuit designs, but the end module 30 and the end module 30 may have a same principle and a same structural scheme. Therefore, after understanding the structure and principle of one of the two end modules, those skilled in the art can, of course, understand the design requirements and specific contents of another. For the sake of brevity, only the end modules 30 is described. As shown in the FIGs, the end module 30 is integrally formed as a generally flat annular shape with an inner diameter and an outer diameter that substantially coincide with the iron core 10. The end module 30 is provided with a plurality of axial openings 31 for the patch cords 20 to pass through. The position of each opening 31 may correspond to the position of each patch cord 20 in the iron core 10. Each opening 31 may be provided with a bonding pad 32 to form an electrical connection with the patch cord 20 through a bonding tip 33 (as shown in FIG. 11), thereby further form an electrical connection with the circuit 34 in the end module 30 (as shown in FIG. 11) via the bonding pad 32, which may be described in further detail later in the present disclosure.
[0047] Referring further to FIG. 11, which is an enlarged schematic view showing an axial sectional view of the end module as shown in FIG. 9. The end module is partially omitted to clearly and concisely show the internal configuration of the end module 30, and especially shows the electrical connection relationship between the patch cord 20 and a corresponding circuit 34 within the end module. As shown in FIG. 11, a bonding pad layer, a circuit layer and a thermal conductor layer 35 may be respectively located from top to bottom along with the axial direction of the end module 30. The bonding pad layer may be composed of a plurality of independent bonding pads 32, and the bonding pads 32 is composed of a conductive material. As shown in FIG. 11, the bonding pad 32 may include a welded end 36 and a circuit end 37. The welded end 36 may be on the surface of the end module and electrically connected to the patch cord 20 via the boding tip 33 generated by welding during assembling the armature. Moreover, the circuit end 37 is located inside the end module and electrically connected with the corresponding circuit 34. Only two circuit layers are shown in FIG. 11. Each circuit layer may comprise a plurality of independent circuits 34. However, the number of the circuit layers may vary as needed, depending on a connection requirement between the plurality of patch cords 20. An insulating layer is disposed between the respective layers. The insulating layer may be an insulating paste, or an insulating fibre to provide electrical insulation while preventing loss of insulation due to overheating as needed. The thermal conductor layer 35 may be located on the other surface of the end module 30 opposite to the bonding pad 32 layer. The thermal conductor layer 35 abuts the iron core 10 when the end module 30 is mounted onto the iron core 10.
[0048] Referring further to FIG. 12, a radial cross-sectional view of the end module 30 of FIG. 9 is shown. As shown in FIG. 12, a plurality of circuits 34 may be arranged in the end module 30. The plurality of circuits 34 are electrically connected to the circuit terminals 36 of the corresponding bonding pad 32. Thus, when the two patch cords 20 are electrically connected to the soldering ends 36 of the corresponding pads 32 by the bonding tips 33, the two patch cords 20 may be connected to each other by the circuit 34 in the end module 30. The two ends of the iron core 10 of the armature 60 may be respectively provided with an end module. The end portion of the patch cord 20 may be electrically connected with other patch cords through the corresponding circuit in the end module corresponding to the end portion. Moreover, another end portion of the patch cord may be electrically connected with another patch cord through the corresponding circuit in the corresponding another end module. Thus, a plurality of patch cords may be sequentially connected by corresponding circuits in the two end modules 30 and 30, until connected to two longer patch cords 20 (see FIG. 1) used as lead wires, thereby forming a complete coil (winding). It is important that since the end module is pre-fabricated, the circuit 34 inside the end module 30 may be arranged according to various techniques in the prior art, such as a printed circuit technology or an integrated circuit technology. The end module 30 may be fabricated to have an unusually small size (along an axis of the iron core 10). That may effectively reduce the size of the armature 60. Since the end module may be electrically connected with the patch cord by various mature techniques in the prior art, such as automatic soldering technology, it is possible to improve production efficiency and yield without performing any bending of the patch cord.
[0049] Referring further to FIGS. 13a-13d, which show various exemplary patch cords 20 that may be used with the armature 60 as shown in FIG. 1. As shown in the FIGs, these patch cords may be generally straight. The configurations of the end modules are different. The patch cord of FIG. 13a may be a hook-shaped end portion. The patch cord of 13b may be a double-eye type end portion. The patch cord of 13c may be a Y-shaped end portion, and the patch cord of 13d may be a fish-eye type end portion. These end portion configurations may be used for one end portion of the patch cord or both end portions of the patch cord. Moreover, the plurality of patch cords may also be selected for other suitable end configurations to meet specific needs, such as facilitating soldering. Moreover, those skilled in the art may understand that the patch cord has various suitable cross sections, but is preferably a flat patch cord with a square cross-section.
[0050] Referring to FIGS. 14a-14e, which illustrate two exemplary methods for assembling the armature as shown in FIG. 1. In FIG. 14a, the core 10 is provided. In FIG. 14b, the insulating paper 40 may be arranged in each notch 11 of the iron core 10. In FIG. 14c, each of the plurality of patch cords 20 may be inserted into the corresponding insulating paper 40. In FIG. 14d, one end module 30 may be mounted onto one end of the iron core 10. Each of the patch cord 20 may be respectively inserted into a corresponding opening 31 in the end module 30. And the corresponding ends of the patch cords 20 may be welded to the welded ends of the corresponding bonding pad 32 on the end module 30. In FIG. 14e, another end module 30 may be mounted onto another end of the iron core 10. Similarly, each of the plurality of patch cords 20 may be inserted into a corresponding opening in the end module 30, and the corresponding end portions of the patch cords 20 may be welded to the welded ends of the corresponding pad on the end module 30. The circuit arrangement of each end module is designed according to the windings that needed to be formed. Moreover, a person skilled in the art can design a corresponding circuit according to the described winding. It may be understood that the respective patch cords may be electrically connected to one another by respective circuits within the end module to form the corresponding windings based on the circuit arrangements within the end module. The end modules can be connected to the patch cords to form circuital connections by various well-established techniques in the prior art, such as automated welding techniques. Since the method does not require any bending of the patch cords, the production efficiency and the yield can be effectively improved.
[0051] FIG. 15 illustrates an armature 60 according to another embodiment of the present disclosure. As shown in FIG. 15, the armature 60 may be similar to the embodiment of FIG. 1 and have an iron core 10, patch cords 20 disposed in the notches of the iron core 10, and an end module 30. The iron core 10 and the end module 30 in the armature 60 as shown in FIG. 15 may have the same configuration and function as the armature as shown in FIG. 1. However, the main difference between the armature as shown in FIG. 15 and the armature as shown in FIG. 1 is that the patch cords 20 are substantially U-shaped, each including two straight segments 21 and one curved segment 22. Each straight segment 21 may be arranged in one of the notches. The curved section 22 may be located outside the notch. Moreover, accordingly, only one end module 30 may be mounted on one axial end of the iron core 10. It can be understood that since the armature uses U-shaped patch cords, the plurality of patch cords only need to be connected to each other at one end to form a complete coil or winding. Therefore, the armature only needs one end module.
[0052] FIG. 16 illustrates an armature 60 according to yet another embodiment of the present disclosure. As shown in FIG. 16, the armature 60 may be similar to the embodiment of FIG. 15 and have an iron core 10, patch cords 20 disposed in the notches of the iron core 10, and an end module 30. The core and patch cords in the armature as shown in FIG. 16 may have the same configuration and function as the armature shown in FIG. 15. However, the main difference between the armature as shown in FIG. 16 and the armature as shown in FIG. 15 is that the end portions of the patch cords 20 are not connected to each other by the end modules. The patch cords 20 are usually connected to each other via a conventional method such as turning, welding, or the like, at the end portions. Conversely, an end module 30 is provided on one end of the iron core 10, and the end module 30 is only used to connect a plurality of specific patch cords through a specific circuit to form a precision shaped line (such as a star point line, a bridge line, etc.).
[0053] The present disclosure has been shown and described in detail concerning the accompanying drawings and the preferred embodiments thereof. But the present disclosure is not limited to the embodiments, and other embodiments derived therefrom are also within the scope of the present disclosure.
