Electric Machine Line Channel Sealing
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Solution Overview
Problem
Existing electrical machines, particularly fluid-cooled motors or generators, face challenges in achieving a compact design while ensuring safe and easy installation of machine connections, especially in cramped conditions where power control electronics are integrated.
Innovation Solution
A machine housing with a line channel for connecting lines, covered by a separating plate with insulating sockets, where connecting bolts are inserted in a position-coded manner to ensure pressure-tight sealing and uniform alignment, utilizing a coding system that allows for different angular orientations of insulating bushings relative to the separating plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If connecting lines are routed through the machine housing, then electrical connections can be established, but the machine design becomes less compact and space is consumed within the housing
Solution Approach 1:
The connecting lines are routed outside the machine housing through a line channel that runs along the outer surface of the housing, transitioning the connection path from the internal three-dimensional space to an external linear path. This dimensional change eliminates the need for internal cable management space while maintaining electrical connectivity.
Solution Approach 2:
The connection system is segmented into distinct functional components: the line channel for routing, the separating plate for isolation, insulating sockets for positioning, and connecting bolts for electrical contact. This segmentation allows each component to be optimized independently and simplifies the overall assembly process.
2Volume of moving object
If cable routing is simplified for compact design, then machine volume is reduced, but safe and easy installation of connections becomes more difficult
Solution Approach 1:
The line channel is pre-configured with insulating sockets positioned at specific locations before final assembly. The connecting lines are routed through this pre-prepared path, and the insulating sockets are already in place to guide and position the connecting bolts, eliminating the need for complex alignment operations during installation.
Solution Approach 2:
The insulating sockets act as intermediary components between the line channel and the connecting bolts. They provide a standardized interface that simplifies the connection process by pre-positioning the bolts and ensuring proper alignment, while also providing electrical isolation between the connecting lines and the conductive housing.
3Volume of moving object
If connecting lines are bent into the line channel, then space requirement is minimized, but sufficient spring or bending distance must be produced for proper contact
Solution Approach 1:
The connecting lines are designed with sufficient length and flexibility to bend into the line channel and make contact with the connecting bolts without requiring external assistance or complex positioning mechanisms. The lines self-adjust to achieve proper contact through their inherent elasticity and bending capability.
Solution Approach 2:
The mechanical properties of the connecting lines are optimized by selecting materials and dimensions that provide the appropriate balance between flexibility for bending and rigidity for maintaining contact. The spring constant and bending radius are carefully controlled to ensure reliable electrical contact while minimizing space requirements.
4Reliability
If a separating plate is used to cover the line channel, then pressure-tight sealing is improved, but device complexity increases
Solution Approach 1:
The separating plate combines multiple functions into a single component: it provides pressure-tight sealing by closing the line channel, supports and positions the insulating sockets, and serves as a mounting surface for the connecting bolts. This merging of functions reduces the overall number of components needed while maintaining sealing reliability.
Solution Approach 2:
The separating plate is designed as a multi-functional element that simultaneously achieves mechanical sealing, electrical isolation, structural support, and alignment guidance. This universal component replaces what would otherwise require multiple separate parts, simplifying the overall device structure while ensuring pressure-tight operation.
Data Source
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AI summary
The invention relates to an electric machine (1) with a machine housing (2) for accommodating a stator (3) and a rotor (4) with stator and/or rotor windings (5), which are connected to connecting lines (8) for producing an electrical contact connection. An isolating plate (16), which covers a line channel (12) for accommodating the connecting lines (8), has a number of insulating bushes (17), into which connecting pins (9, 10) are inserted which can be brought into contact with the connecting lines (8). In this case, the connecting pins (9, 10) with respect to the insulating bushes (17) and preferably the insulating bushes (17) are inserted into the isolating plate (16) in position-coded or angle-coded fashion with respect to said isolating plate.