Cooling Fan Motor Wire Holder Layout for Precise Phase Welding
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Solution Overview
Problem
The reliable orientation and positioning of winding ends of a stator winding as phase connections during the welding process in brushless electric motors are challenging due to the complexity of aligning and securing them with connecting contacts.
Innovation Solution
The electric motor design incorporates wire holders that align and guide the winding ends in pairs, with a connecting cable and hook-shaped contacts, ensuring precise positioning and preventing escape or misalignment during welding, using a plastic jacket and base plate with press-in slots for secure contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the winding ends are guided freely to connecting contacts during welding, then the welding process is simple, but the orientation and positioning reliability deteriorates
Solution Approach 1:
The patent introduces wire holders as intermediary components between the winding ends and connecting contacts. These wire holders pre-position and guide the winding ends in pairs, ensuring reliable orientation and positioning during the welding process without complicating the overall manufacturing procedure.
2Manufacturing precision
If wire holders are introduced to guide winding ends, then the positioning precision improves, but the device complexity increases
Solution Approach 1:
The patent segments the guidance function by providing separate wire holders for different phases (e.g., three wire holders for three-phase motors). Each wire holder independently guides a pair of winding ends, simplifying the design of each individual component while achieving overall precise positioning through the coordinated system.
3Measurement precision
If multiple wire holders are used for different phases, then the alignment accuracy for each phase improves, but the number of components increases
Solution Approach 1:
The wire holders are designed with universal applicability across different phases of the motor. Each wire holder performs the same guidance and alignment function for its assigned phase, allowing for standardized manufacturing and assembly. The repeating modular design ensures consistent alignment accuracy while enabling efficient production through component standardization.
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 configuration ensures reliable and precise alignment of winding ends with connecting contacts, facilitating efficient welding and preventing misalignment or escape, thereby enhancing the electrical connection reliability in brushless electric motors.
Implementation Method 1
the stator is provided with a stator winding or rotating-field winding, with which a magnetic rotating field is generated as a result of the application of an alternating current thereto. The rotor arranged in the substantially hollow cylindrical stator is generally fitted with permanent magnets, which generate a rotor magnetic field interacting with the rotating field of the stator.
Data Source
AI summary
An electric motor, in particular a cooling fan motor of a motor vehicle, has a stator with a stator winding. The winding ends of the stator winding project beyond the stator in the form of phase connections and are oriented in an axial direction in pairs. The motor further has a rotor which is rotatably mounted relative to the stator, a motor support with through-openings for the phase connections, a connection cable with connection contacts for contacting the winding ends, and a number of wire holders, through which the winding ends are guided in pairs and thus in a mutually facing orientation.