Electric Machine Interconnector Assembly With Gasket-Sealed Phase Outputs
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Solution Overview
Problem
Existing liquid-cooled electrical machines face challenges with complex and expensive hydraulic circuits due to sealing problems related to expansion and vibration, leading to potential resin leakage and corrosion, which can damage the machine and hinder coolant circulation.
Innovation Solution
A pre-assembled interconnector assembly with a support body and sealing gasket, allowing for reliable sealing before mounting on the machine, reducing the risk of resin leakage and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flexible membrane is used to seal the connection housing, then sealing is achieved, but resin leakage occurs between the membrane and the body or reservoir
Solution Approach 1:
A sealing gasket is introduced as an intermediary element between the support body and the interconnector housing. This gasket mediates the sealing function, preventing direct contact and potential leakage paths between the flexible membrane and the housing body or reservoir, thereby eliminating resin leakage while maintaining sealing reliability
Solution Approach 2:
The sealing system is segmented into multiple independent sealing interfaces: one between the support body and sealing gasket, another between the sealing gasket and interconnector housing, and a third between the reservoir and interconnector housing. This segmentation isolates potential leakage paths and allows each interface to be optimized independently, preventing resin leakage
2Ease of manufacture
If the interconnector is assembled inside the bearing, then integration is achieved, but manufacturing complexity increases and resin leakage risk increases
Solution Approach 1:
The interconnector assembly is segmented into a support body and an interconnector housing that can be assembled separately outside the bearing, then mounted as a complete unit to the bearing. This reduces manufacturing complexity by allowing pre-assembly and quality control outside the constrained bearing space, while maintaining integration through the mounting connection
Solution Approach 2:
The sealing gasket is pre-installed on the support body before mounting to the interconnector housing and bearing. This preliminary action ensures proper sealing configuration is established before final assembly, reducing the risk of resin leakage and simplifying the manufacturing process by separating complex sealing operations from the final installation step
3Ease of operation
If the phase output is inserted through the flexible membrane, then connection is achieved, but the membrane may displace, tear or stretch causing resin leakage
Solution Approach 1:
The sealing gasket serves as an intermediary structure that receives the phase output insertion while distributing mechanical stresses. Instead of the flexible membrane directly bearing the mechanical load of phase output insertion, the gasket mediates this interaction, preventing displacement, tearing or stretching of the membrane while maintaining connection ease
Solution Approach 2:
The sealing gasket is installed beforehand to provide a cushioning effect that absorbs and distributes mechanical stresses during phase output insertion. This pre-positioned cushioning structure prevents concentrated stresses that would cause membrane displacement, tearing or stretching, thereby maintaining membrane integrity while allowing easy connection
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
One aspect of the invention relates to an assembly E for an interconnector E1 intended to be mounted on a supporting part, such as a bearing of a liquid-cooled electric machine, for the purpose of connecting phase outputs (4) of a winding to power electronics. The assembly E comprises an interconnector housing (1) including a connection recess through hole (100) intended to be filled with resin and to have a phase output (4) pass therethrough, and a connection end (114) of a track for connection to the phase output (4) in a connection recess (500). The assembly E further comprises at least one load-bearing body (2) that differs from a bearing, is fastened to the interconnector housing (1) and includes at least one phase output passage (200) and at least one gasket (3), which is mounted in a compressed state between the load-bearing body (2) and the interconnector housing (1) and comprises a sealing opening (300).