Elastic Winding Temperature Sensor Mount for Accurate Stator Sensing
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Solution Overview
Problem
The integration of temperature sensors within electric machine windings is challenging due to the compact and complex geometry of hairpin or bar wave windings, leading to inaccurate temperature measurements and complications in sensor placement, especially since the hottest point is often inaccessible.
Innovation Solution
A temperature sensor is arranged on an elastic support placed within an elongate recess of the winding, allowing for precise positioning and thermal contact, with the support being designed for flexibility and insulating properties to measure the winding surface temperature accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the temperature sensor is installed inside the stator at an early stage of production, then the temperature measurement position is fixed, but the measurement accuracy decreases due to distance from the winding and interference from cooling media
Solution Approach 1:
The support element is designed to be flexible rather than rigid, allowing it to dynamically adapt its shape to match the winding surface contour. This flexibility enables the temperature sensor to maintain optimal thermal contact with the winding while accommodating variations in winding geometry, thereby improving measurement accuracy without requiring complex rigid positioning structures.
Solution Approach 2:
The support element's physical state is changed from rigid to flexible, allowing it to deform and conform to the winding surface. This parameter change enables the sensor to achieve better thermal contact with the winding while simplifying the installation process, as the flexible support naturally adapts to the winding geometry rather than requiring precise mechanical positioning.
2Measurement precision
If the temperature sensor is placed close to the winding to improve measurement accuracy, then measurement precision improves, but the device complexity increases due to difficulty in arranging the sensor on tightly-wound windings
Solution Approach 1:
The support element is designed as a flexible component that can conform to the tightly-wound winding geometry. This flexible support carries the temperature sensor and allows it to be placed in close proximity to the winding surface, improving measurement accuracy while simplifying integration into compact winding structures that would be difficult to access with rigid mounting methods.
Solution Approach 2:
The flexible support element acts as an intermediary between the temperature sensor and the winding surface. It enables the sensor to achieve close thermal contact with the winding for accurate measurement while simplifying the integration process, as the support can be inserted through existing openings and will naturally conform to the winding geometry without requiring complex assembly procedures.
3Measurement precision
If the support is made elastic to press the sensor into thermal contact with the winding, then thermal contact and measurement accuracy improve, but the support complexity increases
Solution Approach 1:
The support element's mechanical property is changed from rigid to flexible, enabling it to elastically deform and press the temperature sensor against the winding surface. This single parameter change achieves improved thermal contact quality and measurement accuracy while avoiding the need for complex spring mechanisms or adjustable pressure systems, thereby not increasing overall device complexity.
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 enables precise and reliable temperature measurement within the winding region, reducing measurement errors and protecting the sensor from external influences, while maintaining a high heat transfer efficiency.
Implementation Method 1
the temperature sensor is pressed into thermal contact with the winding by the support
Implementation Method 2
the support is designed in such a way that it has an insulating effect on the laminated core, so that the temperature of the winding surface and not of the laminated core is actually measured
Data Source
AI summary
An electric machine includes a stator having a winding, and at least one temperature sensor for detecting the temperature in the region of the winding. The temperature sensor is arranged on an elongate support that is elastic at least in the region of the temperature sensor. The support is placed in an elongate recess which is open to at least one of the sides of the windings and the temperature sensor is pressed into thermal contact with the winding by the support.