System for radially inserting a thermistor into a stator core

Abstract

This invention relates to a radially insertable thermistor assembly for mounting into a stator having multiple stator windings. The radially insertable thermistor assembly includes a thermistor housing having one or more radially outwardly extending elements that extend through a gap between two adjacent stator windings and are operable to connect to the stator and one of the multiple stator windings; and the thermistor housing has a sensing element disposed thereon.

Description

[0001] Cross-application of related applications

[0002] This application claims the benefit of the earlier filing date of U.S. Application No. 62 / 936,092, filed on November 15, 2019, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] Exemplary embodiments relate to the field of electric motors, and more specifically, to a system for radially inserting a thermistor into the stator core of an electric motor. Background Technology

[0004] Thermistors are used to monitor the temperature of various parts of an electric motor. In the case of electric motors used in motor vehicles, one or more thermistors can be placed on the busbar, and one or more thermistors can be mounted on the stator. Various molding techniques can be used when mounting the thermistors to the busbar. For example, the thermistor can be molded together with the busbar, or it can be mounted on the busbar and then molded over it.

[0005] For the stator, thermistors can be held in place using a wire harness or secured to the stator with heat shrink tubing. In some stator applications, thermistors can be threaded into the stator. When in place, the thermistors can be covered with varnish. Existing techniques for mounting thermistors to the stator are labor-intensive and often result in inadequate bonding, inconsistent placement, and insufficient sensing, such as if the thermistor becomes loose before varnish is applied. Therefore, the industry will welcome new technologies for mounting thermistors to the stator core. Summary of the Invention

[0006] This document discloses a radially insertable thermistor assembly for mounting in a stator having multiple stator windings. The radially insertable thermistor assembly includes a thermistor housing having one or more radially outwardly extending elements that extend through a gap between two adjacent stator windings and are operable to connect to the stator and one of the multiple stator windings; and the thermistor housing has a sensing element disposed thereon.

[0007] This document also discloses a stator including a stator core and a plurality of stator windings supported by the stator core. The plurality of stator windings include a gap. A radially insertable thermistor assembly is positioned in the gap, contacting at least one adjacent stator winding among the plurality of stator windings. The radially insertable thermistor assembly includes a thermistor housing having one or more radially outwardly extending elements extending through the gap defined between adjacent stator windings and operable to connect to the stator and one of the plurality of stator windings; and the thermistor housing has a sensing element disposed thereon. Attached Figure Description

[0008] The following description should not be construed as limiting in any way. Referring to the accompanying drawings, similar element numbers are similar:

[0009] Figure 1 A stator and radially insertable thermistor according to one aspect of an exemplary embodiment are described;

[0010] Figure 2 One aspect according to an exemplary embodiment is described. Figure 1 A transparent view of the radially insertable thermistor;

[0011] Figure 3 A stator according to another aspect of an exemplary embodiment is described, which includes a radially insertable thermistor;

[0012] Figure 4 One aspect according to an exemplary embodiment is described. Figure 3 A side view of a portion of the radially insertable thermistor;

[0013] Figure 5 Described according to exemplary aspects Figure 4 A radially insertable thermistor is shown, which illustrates a sensing cable extending from the thermistor housing.

[0014] Figure 6 A radially insertable clip, according to another aspect of an exemplary embodiment, is described;

[0015] Figure 7 A radially insertable clip according to another aspect of an exemplary embodiment is described;

[0016] Figure 8 A radially insertable clip is described according to another exemplary aspect;

[0017] Figure 9 A side view of a radially insertable thermistor with an angled cable outlet, according to an exemplary aspect, is described; and

[0018] Figure 10 Described according to exemplary aspects Figure 8 A top view of a radially insertable thermistor. Detailed Implementation

[0019] Referring to the accompanying drawings, this document provides a detailed description of one or more embodiments of the disclosed apparatus and methods by way of example and not limitation.

[0020] refer to Figure 1 The stator 10 is shown as including a stator body or core 16 and a plurality of stator windings 18. The plurality of stator windings 18 are supported by the stator core 16 and include a gap 24. The gap 24 is defined between adjacent stator windings of the plurality of stator windings 18. The gap 24 extends radially through the plurality of stator windings 18 along a surface of the stator core 16. A thermistor assembly 30 is mounted into the gap 24. The thermistor assembly 30 includes a thermistor housing 36 having a protrusion 40 extending radially through the gap 24. The protrusion 40 contacts at least an adjacent stator winding of the plurality of stator windings 18.

[0021] like Figure 2 As shown, the thermistor housing 36 may include a hollow interior 44 that can receive one or more sensing elements 50 connected to signal wires, one of which is indicated by 51 and may be encapsulated in an outer sheath 54. The sensing element 50 may be in the form of a temperature sensing component, such as a thermistor, a resistance temperature detector, a thermocouple, or the like. A certain amount of filler material 56, such as epoxy resin, is introduced into the hollow interior 44. The filler material 56 holds the sensing element 50 in place and protects it. The protrusion 40 may include a plurality of barbs or radially outwardly extending elements 60 configured to clamp the winding 18 when the thermistor assembly 30 is mounted into the gap 24. The radially outwardly extending elements 60 may be flexible to allow easy deflection upon insertion, or they may be rigid, thus requiring force to push the thermistor housing 36 into the gap 24.

[0022] In this regard, it should be understood that the thermistor housing 36 may be formed of plastic and injection molded onto the sensing element 50. Furthermore, the sensing element 50 may be part of an assembly (not shown) pressed and / or snapped into the thermistor housing 36. In another embodiment, the thermistor assembly 30 may include more than one thermistor housing 36 and associated sensing element 50, arranged in different gaps 24. Furthermore, it should be understood that once installed, the housing can be held in place not only by the barbs 60 but also by a layer of varnish and / or adhesive.

[0023] Now refer to Figure 3-5In the description of another aspect of the thermistor housing 100 according to an exemplary embodiment, similar reference numerals denote corresponding portions in the corresponding views. The thermistor housing 100 includes a body 104 having a hollow interior 106 defined by an inner surface (not shown separately) having an opening 107 and an outer surface 108. When mounted in a stator 10, the outer surface 108 contacts at least adjacent stator windings of a plurality of stator windings 18. A plurality of radially outwardly extending elements may be provided on the outer surface 108, one of which is shown as 110. In this way, the body 104 may form a protrusion associated with a gap 24. The radially outwardly extending element 110 engages at least adjacent stator windings of a plurality of stator windings 18 to secure the thermistor housing 100 to the stator 10.

[0024] One of the sensing elements, designated 114, can be installed within the hollow interior 106. Sensing element 114 can take the form of a temperature sensing component connected to sensor leads 116a and 116b, which extend as sensing cables from the opening 107, for example... Figure 5 As shown in 118. Once installed, the hollow interior 106 can be filled with a filler material, such as epoxy resin. Figure 5 A stop member 120 is also described, which takes the form of first and second outwardly extending protrusions, one of which is designated 122. In one embodiment, the stop member 120 may extend completely around the housing body 104. The stop member 120 limits the depth to which the thermistor housing 100 is inserted into the gap 24. That is, the stop member 120 engages with the adjacent winding 18 to limit the insertion depth of the thermistor housing 100. In this way, the stop member 120 and the radially outwardly extending element 110 prevent the thermistor housing 100 from being inserted deeper into the stator 10.

[0025] In exemplary aspects, for example Figure 6 The clamp member 124 shown can be mounted in the winding 18 to support the sensing cable 118. The clamp member 124 may include a housing 126 and a cable support, which may take the form of a flexible clamp element 128 that can be bent or folded around the sensing cable 118. In one embodiment, the housing 126 includes an opening 129 for receiving a hook element 130 on the clamp element 128. The hook element 130 engages with the housing 126 to retain the sensing cable 118. At this point, the thermistor housing 100 and the clamp member 124 form a thermistor assembly for the stator 10.

[0026] Figure 7 A clamp member 132 according to another exemplary aspect is described. The clamp member 132 includes, for example, a cable support 134 for holding the sensing cable 118. Figure 8A clamp member 140 according to another exemplary aspect is described. The clamp member 140 includes a cable support 150 comprising a first support member 152 and a second support member 154 extending from a stop member 156. The first support member 152 and the second support member 154 are spaced apart from each other by a gap 158 that can receive and support, for example, a sensing cable 118. The clamp member 140 may also include a protrusion 160 having a plurality of radially outwardly projecting elements 162. The protrusion 160 extends into a gap 24, wherein the radially outwardly projecting elements 162 engage with a stator winding 18. The radially outwardly projecting elements 162 may include an inclined surface 164 that facilitates insertion into the gap 124 while preventing its removal.

[0027] Now refer to Figure 9 and Figure 10 Description of a thermistor housing 200 according to another exemplary aspect. Housing 200 includes a body 204 having a hollow interior 206 defined by an inner surface (not separately indicated) and an outer surface 208. A plurality of radially outwardly extending elements may be disposed on one side of the outer surface 208, one of which is shown as 210. Optionally, the radially outwardly extending elements 210 may be disposed on multiple sides of the outer surface 208. In a manner similar to that described herein, the radially outwardly extending elements 110 secure the body 204 in a gap 24. In this way, housing 200 may form a protrusion associated with the gap 24. One of the sensing elements, indicated by 214, may be mounted into the hollow interior 206. Once mounted, the hollow interior 206 may be filled with a filler material, such as epoxy resin. Sensing element 214 may be connected to sensor leads 216a and 216b, which extend from housing 200 as sensing cables 218.

[0028] In one embodiment, the sensing element 214 is arranged in the sensing section 230, and the sensing cable 218 extends from the cable exit section 232. The cable exit section 232 extends from the sensing section 230 at a substantially perpendicular angle. In this way, the cable exit section 232 can relieve stress on the cable 218. The geometry of the housing 200 eliminates the need for any sharp bends in the cable 218 to create the desired route to the controller.

[0029] In one embodiment, a radially outwardly extending member 210 is disposed on a single surface of the outer surface 208. Specifically, when installed in the gap 24, the housing 200 includes an upper surface 260, a lower surface 262, a first radially outer surface 264, and a second radially outer surface 266. The radially outwardly extending member 210 is disposed on the upper surface 260 such that the first radially outer surface 264 and the second radially outer surface 266 are in direct contact with the stator winding 18. In this way, heat transfer to the housing 200 can be enhanced.

[0030] In this regard, it should be understood that the exemplary embodiment provides a system for radially inserting a thermistor into the stator. The thermistor is arranged in a housing having a protrusion that can extend through the gap between adjacent stator windings. The protrusion may include barbs that clamp the windings to hold the housing in position.

[0031] The terms “approximately” and “substantially” are intended to include the degree of error associated with measurements of a specific quantity based on the equipment available at the time of application submission. For example, “approximately” and / or “substantially” may include a range of ±8%, 5%, or 2% of a given value.

[0032] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that, when used in this specification, the terms “comprising” and / or “including” specify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or combinations thereof.

[0033] Although the invention has been described with reference to one or more exemplary embodiments, those skilled in the art will understand that various changes can be made without departing from the scope of the invention, and equivalents can replace its elements. Furthermore, many modifications can be made to adapt particular situations or materials to the teachings of the invention without departing from the essential scope of the invention. Therefore, the invention is not limited to the specific embodiments disclosed as the best mode for carrying out the invention, but rather the invention will include all embodiments falling within the scope of the claims.

Claims

1. A radially insertable thermistor assembly for mounting into a stator having a plurality of stator windings, the radially insertable thermistor assembly comprising: A thermistor housing includes a sensing portion and a cable exit portion extending substantially perpendicularly from the sensing portion. The thermistor housing has one or more outwardly extending elements that extend through a gap defined between two adjacent stator windings and are operable to connect to the stator and one of the plurality of stator windings; and the thermistor housing has sensing elements disposed thereon.

2. The radially insertable thermistor assembly of claim 1, wherein, The thermistor housing includes a body with a hollow interior that can receive the sensing element.

3. The radially insertable thermistor assembly of claim 2, wherein, The sensing element includes a temperature sensing component.

4. The radially insertable thermistor assembly of claim 2, wherein, The sensing element is encapsulated in a filling material disposed inside the hollow cavity.

5. The radially insertable thermistor assembly of claim 2, wherein, The thermistor housing includes a protrusion having an outer surface and a plurality of radially outwardly extending elements extending from the outer surface.

6. The radially insertable thermistor assembly of claim 5, wherein, The plurality of radially outward-extending elements are flexible.

7. The radially insertable thermistor assembly of claim 5, wherein, The thermistor housing includes an upper surface, a lower surface, a first outer surface, and a second outer surface, and the plurality of outwardly extending elements are disposed on only one of the upper surface, the lower surface, the first outer surface, and the second outer surface.

8. The radially insertable thermistor assembly of claim 7, wherein, The plurality of outwardly extending elements are disposed on the upper surface.

9. The radially insertable thermistor assembly of claim 2, wherein, The hollow interior includes an opening extending through the body and a sensing cable extending from the opening.

10. The radially insertable thermistor assembly of claim 1, further comprising: A clamp component, including a cable support, is insertable between adjacent stator windings in the plurality of stator windings.

11. The radially insertable thermistor assembly of claim 10, wherein, The cable support includes flexible clamp elements.

12. A stator, comprising: Stator core; Multiple stator windings, the multiple stator windings being supported by the stator core, the multiple stator windings including gaps; as well as A radially insertable thermistor assembly, positioned within the gap and in contact with at least an adjacent stator winding of the plurality of stator windings, the radially insertable thermistor assembly comprising: A thermistor housing includes a sensing portion and a cable exit portion extending substantially perpendicularly from the sensing portion. The thermistor housing includes a first end, a second end, an intermediate portion defined between the first and second ends, and a plurality of outwardly extending elements projecting outward from the intermediate portion. The first end and the intermediate portion extend into a gap defined between the intersection of two adjacent stator windings. The thermistor housing is connected to the stator and one of the plurality of stator windings. The thermistor housing also has sensing elements disposed thereon.

13. The stator of claim 12, wherein, The thermistor housing includes a body with a hollow interior that can receive the sensing element.

14. The stator according to claim 13, wherein, The sensing element includes a temperature sensing component.

15. The stator of claim 13, wherein, The sensing element is encapsulated in a filling material, which is disposed inside the hollow cavity.

16. The stator of claim 13, wherein, The thermistor housing includes a protrusion having an outer surface and a plurality of outwardly extending elements extending from the outer surface.

17. The stator of claim 16, wherein, The thermistor housing includes an upper surface, a lower surface, a first outer surface, and a second outer surface, and the plurality of outwardly extending elements are disposed on only one of the upper surface, the lower surface, the first outer surface, and the second outer surface.

18. The stator of claim 13, further comprising: A clamp component, including a cable support, is insertable between adjacent stator windings in the plurality of stator windings.

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