Busbar Sensor Fastener for Accurate Inner Winding Temperature
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Solution Overview
Problem
Existing temperature measurement methods in electric machine windings, particularly in densely wound configurations like hairpin or bar-wave windings, are inadequate as they cannot accurately measure temperatures at the radially inner edges due to the tight winding, leading to underestimation of maximum temperatures.
Innovation Solution
A sensor fastener system that includes a busbar assembly with bending elements and a connecting ring, allowing a temperature sensor to be positioned directly at the free ends of the bending elements for precise temperature measurement, without the need for complex integration between windings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If temperature sensors are installed inside the stator for densely wound configurations, then the windings can be tightly wound to achieve compact design, but the temperature sensors become inaccessible for maintenance and cannot be properly positioned to measure maximum temperatures
Solution Approach 1:
The temperature measurement function is segmented from the winding structure itself. Instead of embedding sensors within the dense windings, the patent uses separate busbar assemblies with bending elements that extend into the winding area. This allows the measurement function to be isolated in accessible locations while the windings maintain their compact density.
Solution Approach 2:
Busbar assemblies with bending elements serve as intermediaries between the accessible exterior and the inaccessible interior winding areas. The bending elements extend through or near the windings to provide thermal coupling without requiring direct sensor insertion into the dense winding structure, thus maintaining both compactness and accessibility.
2Ease of operation
If temperature sensors are positioned on the radially outer side of the winding, then the sensors are easily accessible, but the measured temperature is lower than the actual maximum temperature at the radially inner edge
Solution Approach 1:
The patent transitions from radial positioning (outer side only) to multi-dimensional positioning by using bending elements that can extend in multiple directions and locations. This allows temperature sensors to be positioned at various points including areas that thermally represent the maximum temperature zones, while maintaining external accessibility through the busbar structure.
Solution Approach 2:
The busbar assemblies with bending elements are pre-configured to extend into positions that thermally couple with the maximum temperature zones of the windings before the windings are fully assembled. This preliminary positioning ensures accurate temperature measurement without requiring subsequent access to the dense winding structure.
3Measurement precision
If temperature sensors are integrated between the windings, then accurate temperature measurement can be achieved, but the assembly process becomes complicated and time-consuming
Solution Approach 1:
The temperature measurement system is segmented into separate modular busbar assemblies that can be independently manufactured and then easily integrated. This eliminates the need for complex integration of sensors within the windings, as the measurement function is provided by separate components that attach to or extend near the windings.
Solution Approach 2:
The busbar assemblies are designed to be self-contained units that provide both electrical connection and temperature measurement functions. The bending elements automatically position the temperature sensors in appropriate locations without requiring manual intervention to place sensors between individual windings, thus simplifying the assembly process.
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
Enables reliable and precise temperature measurement of electric machine windings, particularly in densely wound configurations, by ensuring a constant thermal connection between the temperature sensor and the winding, thus providing accurate temperature data for monitoring and maintenance.
Implementation Method 1
the temperature of the free ends can be measured by a temperature sensor
Data Source
AI summary
The disclosure relates to a sensor fastener for measuring a temperature on a busbar assembly with a busbar, said assembly has at least one busbar assembly with at least one busbar. One or more busbars have bending elements, each of which has a free end; and a connecting ring for connecting to the busbar assembly. The bending elements extend through the connecting ring such that the free ends are free-standing in such a manner that the temperature of the free ends can be measured by a temperature sensor, thereby allowing a precise measurement of the temperature in a winding of an electric machine for a motor vehicle.