Isolation Ring With Flexible Arm Sensor Seat for Stator Temperature Detection

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Solution Overview

Problem

Existing methods for accurately detecting the temperature of stator coil windings in electrical machines, such as those in hybrid electric vehicles, face challenges in reliable contact and efficient arrangement of temperature sensors, leading to potential inaccuracies and increased time and cost.

Innovation Solution

An isolation ring with a protrusion and conductor guide, featuring a flexible arm with a sensor seat and a heat shrink tube rubber strap, ensures reliable contact of the temperature sensor with the electrical conductor, allowing for accurate and self-adjusting temperature detection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the temperature sensor is arranged in the slot, then the temperature of the conductors can be detected, but it is necessary that the sensor is reliably in contact with the conductor and the arrangement is time and cost intensive

Engineering Contradiction:

Improvetemperature detection accuracyVSAvoidsensor arrangement complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent introduces a flexible arm with a sensor seat as an intermediary component between the temperature sensor and the conductor. The sensor seat is movable along the conductor and can be positioned to ensure reliable contact, while the flexible arm provides the necessary compliance and adjustment capability. This mediator structure simplifies the overall arrangement by providing a built-in mechanism for achieving reliable contact without complex external positioning systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If the temperature sensor is arranged in the slot, then the temperature of the conductors can be detected, but the arrangement is time and cost intensive

Engineering Contradiction:

Improvetemperature detection accuracyVSAvoidsensor arrangement time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The flexible arm with sensor seat is designed to automatically adjust and position itself along the conductor to achieve reliable contact. The spring element or elastic deformation capability of the flexible arm allows it to self-adjust to the conductor's position and shape, eliminating the need for manual positioning and reducing assembly time. The structure serves itself by using its own elasticity to maintain contact pressure and position.

Inventive Principle:

Principle #25Self-service

3Reliability

If a rigid structure is used for the sensor holder, then the sensor position is fixed, but it cannot adapt to conductor position variations

Engineering Contradiction:

Improvesensor contact reliabilityVSAvoidconductor position adaptation

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent employs a dynamic flexible arm structure that can move and deform to adapt to variations in conductor position. The flexible arm, potentially with spring elements or elastic material, provides continuous adjustment capability while maintaining reliable contact. This dynamic structure allows the sensor to follow conductor movements and position changes, ensuring consistent measurement reliability across different operating conditions.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The flexible arm is constructed using flexible materials or thin-walled structures that can bend and deform to match the conductor's position and shape. This flexible construction allows the sensor holder to conform to the conductor's geometry and position variations, maintaining reliable contact without requiring rigid positioning mechanisms. The flexibility enables adaptation while the sensor seat maintains stable contact with the conductor surface.

Inventive Principle:

Principle #30Flexible shells and thin films

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 provides a cost-effective and reliable means for precise temperature measurement of stator end windings, particularly at the neutral bridge, which is the hottest area, enhancing the safety and efficiency of electrical machines.

Implementation Method 1

the rubber strap (36) is a heat shrink tube layer (46)

Methodology Applied

Scientific EffectHeat shrinkage: Thermal Contraction

Data Source

PatentEP3562004B1Isolation ring for isolating end windings of a starter generator for a hybrid electric vehicle

Publication Date: 2022.05.11 VITESCO TECHNOLOGIES GMBH

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AI summary

The invention concerns to an isolation ring (10) for isolating the end windings of a stator of an electrical machine, comprising a protrusion (12) with an insertion opening (18) and a conductor guide (14), wherein an end of an electrical conductor (16) is insertable through the insertion opening (18) into the conductor guide (14), wherein the protrusion (12) comprises a flexible arm (20) with a sensor seat (22) on an inner side of the flexible arm (20) facing the conductor guide (14), and the flexible arm (20) is at least partially moveable in a direction of the conductor guide (14), a temperature sensor (24) arranged in the sensor seat (22) facing the conductor guide (14), and a rubber strap (36) arranged around the protrusion (12) in such a way that it exerts a force (38) moving the flexible arm (20) in the direction of the conductor guide (14).