Insulating Ring Lever Mount for Stator Winding Temperature Sensors
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Solution Overview
Problem
Existing electric motors face challenges in achieving simple and safe assembly and operation, particularly in securely attaching temperature sensors to stator windings while ensuring insulation and protection against damage.
Innovation Solution
The design incorporates a stator winding with a temperature sensor and an insulating ring featuring a lever mechanism that allows easy assembly by sliding the insulating ring into place before potting, followed by elastic pressing of the sensor against the stator, and a connection ring that secures the sensor to the stator winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor is rigidly fixed to the stator winding, then the sensor is securely attached, but the assembly process becomes complex and the sensor is vulnerable to damage during assembly
Solution Approach 1:
The insulating ring incorporates a lever area that can be moved between a first position (during assembly) and a second position (after assembly). This dynamic element allows the sensor to be tilted away from the stator winding during assembly to avoid damage, and then pressed against the stator winding after assembly for secure attachment and accurate temperature measurement.
Solution Approach 2:
The insulating ring is designed with a lever area that preliminarily protects the sensor during assembly by maintaining it in a tilted, non-contact position with respect to the stator winding. This preliminary protective action prevents damage before the sensor needs to be securely attached for operation.
2Reliability
If the insulating ring is slid into place after potting compound is applied, then the sensor is securely positioned, but the assembly process becomes more difficult and time-consuming
Solution Approach 1:
The insulating ring with the movable lever area is designed to be slid into place before the potting compound is applied. The lever area is then actuated to press the sensor against the stator winding, and finally the potting compound is applied to permanently secure the assembly. This preliminary positioning action simplifies the assembly process while ensuring accurate sensor positioning.
3Measurement precision
If the sensor is pressed against the stator winding with high force, then temperature measurement accuracy is improved, but the sensor may be damaged during assembly
Solution Approach 1:
The lever area of the insulating ring provides a dynamic mounting mechanism that allows the sensor to be tilted away from the stator winding during assembly, eliminating damage risk. After assembly, the lever area is actuated to press the sensor against the stator winding with sufficient force for accurate temperature measurement, and the potting compound permanently secures this position.
Solution Approach 2:
The insulating ring with its movable lever area provides beforehand protection for the sensor during assembly by maintaining it in a non-contact, tilted position relative to the stator winding. This preliminary cushioning prevents damage before the high-force contact is needed for accurate measurement.
4Ease of manufacture
If the insulating ring is made as a single rigid piece, then manufacturing is simplified, but the sensor cannot be tilted for easy assembly
Solution Approach 1:
The insulating ring is designed with a lever area that is rotationally connected to the main body through rotational areas with reduced material thickness. This segmentation allows the lever area to move independently between a first position (tilted) and a second position (contacting), enabling easy assembly while maintaining manufacturing simplicity through integral formation with projections.
Solution Approach 2:
The insulating ring incorporates a movable lever area connected through rotational areas, transforming it from a static rigid structure to a dynamic element that can be actuated during assembly. This dynamic design enables the sensor to be tilted for easy assembly while maintaining manufacturing simplicity through integral formation.
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 facilitates safe and efficient assembly by securely attaching the sensor, enhancing insulation and protection, reducing the risk of damage during assembly, and ensuring reliable electrical connections.
Implementation Method 1
the sensor is elastically pressed against the stator winding by the lever area
Implementation Method 2
the lever area, on its side facing away from the first rotational area in the circumferential direction, is connected to the second of the two projections via a second rotational area, in particular wherein the two rotational areas are formed with a smaller material thickness than the lever area and the respective projection
Data Source
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AI summary
The invention relates to an electric motor with stator winding, sensor and insulating ring, wherein a lever region is formed on the insulating ring in which the sensor is received. The sensor is pressed elastically against the stator winding by the lever region.