Connection Ring Arrangement With Elastic Projections
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Solution Overview
Problem
Existing electric motor connection ring arrangements are complex and costly to manufacture, requiring intricate die designs for encapsulation and positioning of conductive busbars, which complicates the production process and increases expenses.
Innovation Solution
A connection ring arrangement featuring a support element with projection arrangements that securely hold conducting rings, allowing for efficient assembly and elimination of complex encapsulation, with projections designed to accommodate multiple conducting rings in a space-saving manner, reducing the need for costly manufacturing methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex encapsulation by plastic injection molding is used to ensure insulation resistance between phases, then insulation reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent uses thin film insulation layers (such as enamel coatings on the conducting rings) instead of thick plastic encapsulation. This provides sufficient electrical insulation between phases while dramatically reducing the complexity of the manufacturing process and eliminating the need for complex injection molding dies.
2Manufacturing precision
If conducting rings are produced by stamping, rolling or shaping in complex dies, then manufacturing precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent changes the manufacturing approach from complex mechanical forming (stamping, rolling) to simpler processes such as extrusion or drawing of the conducting rings. The required geometric precision is achieved through optimized design of the ring cross-section and support element interface, rather than through complex forming operations.
3Manufacturing precision
If complex dies for insulators in the stator are used to receive the connection ring, then positioning precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent divides the positioning function into separate elements: the support element provides mechanical support and positioning, while the conducting rings are independently formed and then assembled. This eliminates the need for complex integrated dies that must simultaneously form both the insulator and positioning features.
Solution Approach 2:
The support element acts as an intermediary component that simplifies the overall manufacturing process. It provides a standardized mounting structure for the conducting rings, eliminating the need for complex custom dies and reducing manufacturing cost while maintaining positioning precision.
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
The solution enables a more efficient and cost-effective production of connection rings, simplifying the assembly process and eliminating the need for complex encapsulation, thereby reducing manufacturing costs and improving the overall efficiency of electric motor construction.
Implementation Method 1
at least one projection is at least partially elastically formed in a direction transverse to the longitudinal direction of the projection
Data Source
AI summary
A connection ring arrangement, includes a plurality of conducting rings, and a support element which holds the plurality of conducting rings. The support element has a projection arrangement having two projections which are designed receive the conducting ring and which extend from said conducting ring. The projection arrangement has an open end and a closed end, which closed end receives the conducting ring. The distance between the projections is at least partially smaller than the diameter of the conducting ring and at least one projection is at least partially elastically formed in a direction transverse to the longitudinal direction of the projection. The projections are designed such that the conducting ring is inserted between the projections.