ECM Winding Connection Force Distribution
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Solution Overview
Problem
Existing electronically commutated motors face issues with pulling and pressing forces at winding connections, which can lead to damage or interruption of the electrically conductive connection between the winding connections and the contact arm, especially during assembly or operation.
Innovation Solution
The motor incorporates an internally threaded part connected to a voltage source, with contact tracks and winding wire contact elements secured to an insulator body, featuring an internal threaded part that allows for screwing of an electrical conductor, reducing forces through axial alignment and secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electric conductors with threaded parts are screwed to winding connections, then electrical connection is established, but pulling and pressing forces occur that can damage the stator or interrupt the electrical connection
Solution Approach 1:
A force distribution element (metal plate) is introduced as an intermediary between the contact arm and the stator winding. This mediator distributes the mechanical forces over a larger area, preventing concentration of forces at the winding connection points and thus avoiding damage while maintaining electrical connectivity.
Solution Approach 2:
The force distribution element is pre-installed on the stator before the contact arm is assembled. This preliminary action ensures that the force distribution structure is already in place to handle the pulling and pressing forces that will occur during operation, preventing connection damage before it happens.
2Ease of operation
If contact arms are positioned at predetermined angles to the motor, then control function is achieved, but axial forces occur at winding connections during assembly
Solution Approach 1:
The force distribution element serves as a mediator that decouples the control arm positioning function from the winding connection points. It allows the contact arms to be positioned at the required predetermined angles for control functionality while absorbing and distributing the resulting axial forces away from the vulnerable winding connections.
3Reliability
If threaded parts are used for securing conductors, then electrical connection is secured, but pulling forces during assembly can damage the stator
Solution Approach 1:
The force distribution element acts as a protective intermediary between the threaded fastening system and the stator. It allows the threaded parts to securely fasten the electrical conductors while intercepting and distributing the harmful pulling forces before they can damage the stator structure.
Solution Approach 2:
The force distribution element provides beforehand cushioning by being pre-positioned to absorb and distribute the pulling forces that will be generated during assembly and operation. This preventive measure cushions the stator against damage before the harmful forces can affect it.
Data Source
AI summary
An electronically commutated motor has a rotor with a permanent magnet arrangement, a stator (30) with a bundle of laminations (32) and a winding (34). The bundle of laminations is, at at least at one axial end (32′), provided with an insulator (41) and the winding (34) has a plurality of coils (38A, 38B, 38C, 38D) that are wound from at least one winding wire (36); at least one winding wire contact element (50) which is attached to an insulator body (41) and mechanically and electrically conductive connected with at least one section (36A) of at least one winding wire (36); at least one contact track (60) with a first section (61) which is mechanically and electrically conductive connected to the winding wire contact element (50), a second section (62) which is arranged with an internal threaded part (65) with an internal thread (66) to enable an electrical connection of the winding (34) to the associated voltage source and a third section (63) which connects the first section (61) with the second section (62) electrically conductive.