Electric Machine Mid-Frame Wire Routing Against Contact Hazards
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Solution Overview
Problem
Existing electrical machine assemblies face issues with excess wiring slack congregating in cavities and undesirable contact between components, leading to potential hazards and inefficiencies during assembly.
Innovation Solution
The implementation of a mid-frame with a guide structure that separates the assembly cavity into compartments, guiding wires away from rotating members and preventing contact, while also incorporating features like sleeves and grooves to manage moisture ingress and enhance cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If sufficient slack is provided in the wiring to allow for electrical coupling, then assembly flexibility is improved, but excess wiring congregates within the cavity creating potential hazards
Solution Approach 1:
The cavity is divided into multiple compartments using a partition structure. The first compartment houses the excess wiring while the second compartment contains the electrical component. This segmentation isolates the harmful excess wiring from the electrical component, eliminating the hazard while preserving the necessary wiring slack for assembly flexibility.
2Ease of operation
If wiring is allowed to extend freely between components, then electrical coupling is facilitated, but contact between wiring and rotating members occurs causing undesirable effects
Solution Approach 1:
The partition structure divides the cavity into separate compartments, isolating the wiring in the first compartment from the rotating member in the second compartment. This physical separation prevents contact between the wiring and rotating member, eliminating the harmful effect while allowing wiring to extend freely within its designated compartment for electrical coupling.
Solution Approach 2:
The partition structure acts as an intermediary barrier between the wiring and the rotating member. It allows the wiring to extend and make electrical connections within the first compartment while preventing any contact with the rotating member in the second compartment, thus mediating between the need for electrical coupling and the need to prevent contact hazards.
3Ease of manufacture
If the cavity is left as a single open space, then component installation is simplified, but moisture ingress affects component reliability
Solution Approach 1:
The cavity is segmented into multiple compartments by the partition structure. This segmentation creates separate sealed environments for different components, preventing moisture ingress from affecting all components uniformly. While the structure becomes more complex, each compartment can be independently sealed, thereby improving reliability without significantly complicating the assembly process.
Data Source
AI summary
An electric machine assembly includes a housing defining an inner cavity and an electrical component positioned within the cavity. The electric machine assembly also includes a mid-frame positioned within the cavity and configured to separate the cavity into a first compartment and a second compartment. The mid-frame includes a guide structure for guiding a plurality of wires through the second compartment toward the electrical component.