Elastic Sensor Support for Stator Winding Temperature Monitoring
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Solution Overview
Problem
The existing methods for installing temperature sensors in rotating electrical machine stators are complex, costly, and prone to errors, requiring precise gap creation and sensor sizing, which increases manufacturing time and risks of damaging the stator turns.
Innovation Solution
A stator design featuring an elastic support for the temperature sensor that can elastically deform to fit between coils, ensuring continuous contact and simplifying the installation process by integrating the sensor with the interconnector, which is then welded to the stator, thereby reducing assembly constraints and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional methods are used to install temperature sensors in stators, then sensor installation is possible, but the installation process becomes complex and time-consuming
Solution Approach 1:
The patent combines the temperature sensor with the interconnector into a single integrated assembly. The sensor is mounted on the interconnector before it is installed in the stator, merging two previously separate components (sensor and interconnector) into one unified structure. This integration eliminates the need for separate sensor installation steps and reduces the overall complexity of the installation process.
Solution Approach 2:
The temperature sensor is pre-mounted on the interconnector before the interconnector is installed in the stator. This preliminary action allows the sensor to be positioned and secured in advance, simplifying the final installation process. The sensor is already in its correct position when the interconnector is placed in the stator, eliminating the need for complex gap creation and sensor positioning operations.
2Productivity
If traditional sensor mounting methods are used, then sensor installation is possible, but manufacturing time increases
Solution Approach 1:
By merging the sensor and interconnector into a single assembly, the patent enables both components to be installed in one operation. The interconnector with the pre-mounted sensor is installed as a single unit in the stator, eliminating the time required for separate sensor installation steps and significantly reducing overall mounting time.
Solution Approach 2:
The sensor is pre-positioned and secured on the interconnector before final installation. This preliminary mounting action allows the sensor to be in its correct position and orientation in advance, eliminating time-consuming adjustments and positioning operations during the final installation process.
3Manufacturing precision
If precise gap creation is performed during sensor installation, then sensor fitting is possible, but the risk of damaging turns increases
Solution Approach 1:
The sensor is pre-mounted on the interconnector in a controlled environment where precise positioning can be achieved without the constraints of the final installation location. This preliminary mounting allows for accurate sensor positioning and secure fastening before the assembly is installed in the stator, eliminating the need to create precise gaps in the tightly wound stator turns.
Solution Approach 2:
The interconnector serves as an intermediary carrier for the temperature sensor. By mounting the sensor on the interconnector first, the patent creates a buffer zone that allows for precise sensor positioning and secure fastening without directly manipulating the stator turns. This intermediary approach eliminates the risk of damaging the turns during sensor installation.
4Reliability
If multiple intervention steps are performed during sensor installation, then proper sensor mounting is possible, but installation cost increases
Solution Approach 1:
By combining the sensor and interconnector into a single integrated assembly, the patent reduces the number of separate installation steps and interventions required. The merged assembly can be installed as one unit, eliminating the need for multiple separate operations and reducing labor costs while maintaining reliable sensor mounting.
Solution Approach 2:
The sensor is pre-mounted and secured on the interconnector in advance, allowing for thorough positioning and fastening operations to be performed before final installation. This preliminary action ensures reliable sensor mounting with proper positioning and secure attachment, while reducing the number of intervention steps required during the final installation 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
The elastic support facilitates easy and secure mounting of the temperature sensor, ensuring continuous contact with the winding for accurate temperature measurement while reducing the complexity and cost of the installation process.
Implementation Method 1
the ability to elastically deform the body of the support for the sensor favorably allows the support to conform to the space available between the interconnector and the stator
Data Source
Figure 1a~1b
Figure 1c~2a
Figure 2b~2c
AI summary
This is a stator (11) of a rotating electrical machine comprising: • an interconnector (22) for interconnecting coils (19); • a winding wound around a stator body (201); • a support (110) comprising an elastic body (111) which has a temperature sensor (101) oriented towards the winding, said elastic body (111) being configured to have along a vertical axis A a first position in which the body (111) is relaxed and a second position in which the body (111) is compressed, the support (110) comprising at least one fixing element (113) having a contact wall (114) which is adapted to be held fixedly and in contact with the interconnector (22), In addition: the support (110) is carried by the interconnector (22) and in that along the vertical axis A, in said second position, the sensor (101) is closer to said wall (114) than in said first position.