Coil Insulator Recess for Temperature Sensor Mounting
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Solution Overview
Problem
Existing electrical machines face challenges in efficiently installing and securely positioning temperature sensors within the stator coils, which can lead to inaccurate temperature measurements due to the presence of a water cooling circuit, potentially resulting in under-evaluation of winding temperatures.
Innovation Solution
A coil insulator with a flexible hollow tab that forms a housing for the temperature sensor, providing elastic retention and maintaining contact with the coil, while also allowing for easy installation and potential use of thermally conductive resin for improved heat transfer and electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a temperature sensor is installed inside the stator coil to measure winding temperature, then measurement precision is improved, but the device complexity increases due to the need for additional housing structures and installation mechanisms
Solution Approach 1:
The patent combines the temperature sensor housing with the coil insulator into a single integrated component. The insulator body incorporates a recess that directly receives and positions the temperature sensor, eliminating the need for separate housing structures. This merging approach maintains precise temperature measurement capability while reducing overall device complexity by consolidating functional elements.
Solution Approach 2:
The coil insulator is designed to serve multiple functions: electrical insulation, mechanical support for the coil, and housing for the temperature sensor. The insulator body integrates these diverse functions into a single component, with the recess providing both structural support and sensor positioning. This multi-functionality approach improves measurement precision while avoiding additional dedicated structures.
2Measurement precision
If a rigid housing structure is used to position the temperature sensor, then measurement precision is maintained, but ease of manufacture deteriorates due to increased manufacturing steps and assembly complexity
Solution Approach 1:
The housing for the temperature sensor is merged with the coil insulator body, forming a single integrated component. The recess is directly formed in the insulator during the molding process, eliminating separate housing parts and assembly steps. This approach maintains precise sensor positioning while significantly improving ease of manufacture through single-step fabrication.
Solution Approach 2:
The patent utilizes the molding process parameters to directly form the recess with precise dimensions and geometry. By controlling the mold cavity parameters, the recess is created with the exact specifications needed for accurate sensor positioning, eliminating the need for secondary machining or assembly operations. This parameter control approach maintains precision while simplifying manufacturing.
3Reliability
If the temperature sensor is positioned away from the coil to avoid water cooling circuit interference, then measurement reliability is improved, but temperature measurement accuracy deteriorates due to increased thermal distance
Solution Approach 1:
The patent creates a localized thermal environment for the temperature sensor by positioning it in a recess within the coil insulator that places it in direct contact with the coil winding. This local positioning ensures the sensor measures the actual winding temperature despite the presence of water cooling circuits elsewhere in the stator. The recess geometry is specifically designed to maximize thermal contact with the coil while maintaining electrical insulation.
Solution Approach 2:
The coil insulator acts as an intermediary structure that enables direct thermal contact between the temperature sensor and the coil winding. The recess in the insulator body provides a controlled interface that facilitates heat transfer from the coil to the sensor while maintaining electrical isolation. This intermediary approach allows the sensor to accurately measure coil temperature even in the presence of cooling circuits.
4Ease of operation
If a flexible tab structure is used to retain the temperature sensor, then ease of operation is improved for sensor installation and removal, but reliability may deteriorate due to potential sensor displacement
Solution Approach 1:
The patent employs a flexible tab formed from the insulator material that can be elastically deformed to facilitate sensor installation. The tab acts as a flexible retaining element that can be pushed aside during assembly to allow sensor insertion, then returns to its original position to secure the sensor. This flexible structure provides easy installation while maintaining reliable sensor retention through elastic recovery.
Solution Approach 2:
The retaining tab is designed with dynamic characteristics, allowing it to change position during installation and then stabilize in a fixed position during operation. The tab can be temporarily displaced to accommodate sensor insertion, then elastically returns to engage and secure the sensor. This dynamic behavior provides ease of operation during assembly while ensuring reliable, stable sensor positioning during machine operation.
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 solution ensures accurate temperature measurement by maintaining sensor contact with the coil, avoiding under-evaluation of winding temperatures and enhancing reliability through dual sensor placement for redundancy.
Implementation Method 1
the lug (301) exerting an elastic action against the temperature sensor (303) so as to keep it in contact with the coil
Implementation Method 2
potential use of thermally conductive resin for improved heat transfer
Data Source
Figure 1~2a
Figure 2b~2c
Figure 3a
AI summary
The invention relates to a coil insulator (20) to be provided around the tooth of a stator of an electric machine. Said coil insulator has a body comprising walls forming a frame as well as a front rim (203) and a rear rim (204) defining, together with the walls of the frame, a mounting groove for winding a coil (19), characterized in that said coil insulator comprises a recess (302, 331', 401) for receiving a temperature sensor. The invention also relates to an interconnector for the stator of the electric machine as well as to a bearing for the corresponding temperature sensor.