Electric Machine Conductor Routing With Separator-Protected Volume
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Solution Overview
Problem
Existing electric machines face challenges in providing a safe, reliable, and easy-to-assemble electrical connection between stator windings and a power source or energy storage device.
Innovation Solution
The electric machine incorporates a separator element between the stator and end wall, creating a volume to house electrical conductors and protect them from the rotor, facilitating assembly and connection to a power source through a cable gland system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical conductors are routed directly from stator to housing opening, then assembly is simple, but conductors are exposed to rotor and operational safety is compromised
Solution Approach 1:
The housing internal space is segmented into multiple regions using separator elements. These separators create distinct zones: a first region for the rotor, a second region for the stator, and a third region for routing electrical conductors. This spatial segmentation protects conductors from rotor exposure while maintaining organized assembly structure.
Solution Approach 2:
Separator elements act as intermediary components between the rotor and electrical conductors. These separators physically isolate the conductors from the rotating parts, serving as a protective barrier that enables safe conductor routing without direct exposure to rotor motion.
2Reliability
If separator elements are added to protect conductors, then operational safety improves, but assembly complexity increases
Solution Approach 1:
The separator elements are designed as modular components that divide the housing internal space into functional zones. This segmentation allows conductors to be routed through protected pathways while the modular nature of separators facilitates standardized manufacturing and assembly procedures.
Solution Approach 2:
The separator elements are pre-formed with specific geometries that include openings and routing paths for electrical conductors. This preliminary preparation of separator structures enables conductors to be easily guided through protected routes during assembly, reducing on-site complexity despite adding protective functionality.
3Reliability
If conductors are protected within a delimited volume, then reliability improves, but device complexity increases
Solution Approach 1:
A delimited volume within the housing is segmented off from the main internal space using separator elements. This creates a protected third region where electrical conductors can be routed and connected with confidence that they are isolated from rotor exposure, while the segmentation maintains clear functional zones throughout the structure.
Solution Approach 2:
The protection strategy extends into the third dimension by creating a delimited volume rather than merely surface-level protection. This volumetric approach, achieved through strategically positioned separator elements, provides comprehensive conductor protection while organizing the internal space into distinct functional layers and zones.
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 design allows for safe, reliable, and cost-effective assembly and operation of the electric machine by protecting electrical conductors from the rotor and enabling easy connection to a power source, enhancing operational safety and efficiency.
Implementation Method 1
a separator element disposed in between the stator and the end wall along the axial direction, the separator element delimiting a volume within the inner space for receiving an electrical conductor within said volume
Data Source
AI summary
An electric machine, comprising: a housing enclosing an inner space, a stator and a rotor disposed in the inner space, an axis of rotation of the rotor defining an axial direction. The housing comprises an end wall extending transverse to the axial direction and closing the inner space in the axial direction. A separator element disposed in between the stator and the end wall along the axial direction, and the separator element delimiting a volume within the inner space for receiving an electrical conductor within said volume.