Vehicle Motor Generator Terminal Block for Accurate Coil Temperature Sensing
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Solution Overview
Problem
Existing motor generators in vehicles face challenges in accurately measuring coil end temperatures due to temperature sensor placement issues, such as positional slip and interference from cooling oil, leading to variations in temperature measurements and increased component and assembly complexity.
Innovation Solution
A terminal block design that houses a resin-molded temperature sensor within a coil end section hole, with a flow restraint member to prevent cooling medium interference, and a cooling medium sump and flow path to stabilize temperature measurements, reducing component count and assembly steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a temperature sensor is attached to a coil end section, then temperature measurement is enabled, but measurement precision deteriorates due to oil spilling onto the sensor
Solution Approach 1:
The patent introduces an intermediary structure (temperature sensor holder with oil seal) between the temperature sensor and the coil end section. This holder includes a through hole that guides the sensor while preventing oil from reaching it, thus mediating the conflict between enabling temperature measurement and preventing oil interference.
Solution Approach 2:
The patent extracts the temperature sensor from direct exposure to the oil environment by housing it within a dedicated holder structure. The sensor is taken out of the harmful oil-filled space and positioned in a protected cavity, eliminating the direct harmful interaction while maintaining measurement capability.
2Measurement precision
If a temperature sensor is fixed to a coil end section, then temperature measurement is enabled, but reliability deteriorates due to positional slip of the sensor
Solution Approach 1:
The temperature sensor holder acts as an intermediary that provides stable positioning for the sensor. The holder's through hole and internal structure mechanically constrain the sensor, preventing positional slip while maintaining its measurement function against the coil end section.
Solution Approach 2:
The sensor is preliminarily positioned and fixed within the holder structure before the coil end section is assembled. This preliminary positioning ensures the sensor maintains a stable, predetermined position relative to the coil, preventing subsequent positional slip during operation.
3Ease of operation
If multiple separate components are used for temperature sensor fixation and terminal connection, then functional requirements are met, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into a single integrated terminal block structure. The terminal block simultaneously serves as the temperature sensor holder, the terminal connection point, and the structural support element, eliminating the need for separate fixation components and reducing overall device complexity.
Solution Approach 2:
The terminal block is designed with multi-functionality, serving both as an electrical terminal for coil connections and as a housing structure for the temperature sensor. This universal component performs multiple functions that would traditionally require separate parts, simplifying the overall device architecture.
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
The solution effectively suppresses temperature measurement variations, ensures accurate temperature sensing, and reduces the number of components and assembly steps by maintaining stable contact and efficient cooling, even under varying conditions.
Implementation Method 1
a temperature sensor for detecting temperature of coil end section that have been resin molded
Implementation Method 2
a motor generator for a vehicle cooled by a cooling medium
Data Source
AI summary
A rotating electrical machine (100) is driven by a three-phase AC current and is provided with a stator core (13), a molded resin (12) for covering a coil wound on the stator core, a rotor core (40), a shaft (11) provided to the rotor core (40), a terminal base (20) provided to a coil end section, and a case (30) for covering the rotating electrical machine (100). Power cables extending from the terminal base (20) are led out of the case (30) through a case terminal box (31). A temperature sensor (22) is affixed in a hole in the molded resin (12) by the terminal base (20) and measures the temperature in the vicinity of a heat producing source.