Electric Motor Phase Lead Sealing for Power Density
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Solution Overview
Problem
Electric motors face challenges in maximizing active motive material within given size constraints while maintaining sealing requirements to prevent outside contaminants, which limits power output and increases complexity and weight.
Innovation Solution
A three-phase electric motor design with a stator and rotor configuration that includes multiple windings and permanent magnets, utilizing heat shrink tubing and crimped wire barrels for phase leads, and separate Wye terminations to maximize active motive material and prevent contaminants, reducing the need for physical connectors and additional wiring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealing components are added to prevent contaminants, then reliability is improved, but device complexity and weight increase
Solution Approach 1:
The patent combines the sealing function with the lead exit hole structure itself. The hole is sized to create an interference fit with the phase leads, eliminating the need for separate sealing components like gaskets or seals. This merging of functions reduces device complexity while maintaining sealing effectiveness.
Solution Approach 2:
The lead exit hole serves multiple functions: it provides electrical lead passage and simultaneously acts as a sealing barrier against contaminants. This multi-functionality eliminates the need for dedicated sealing components, reducing both complexity and weight while maintaining reliability.
2Reliability
If physical connectors and additional wiring are used, then reliability is improved, but device complexity and weight increase
Solution Approach 1:
The patent extracts and eliminates unnecessary physical connectors and additional wiring from the system. The phase leads are directly routed through the lead exit holes with interference-fit sealing, removing intermediate connectors and simplifying the wiring architecture while maintaining connection reliability.
Solution Approach 2:
The phase leads themselves serve as both the electrical connection and the sealing element. The interference fit between the leads and the lead exit holes creates an automatic seal without requiring separate sealing components, allowing the system to seal itself through its existing structures.
3Power
If more active motive material is added, then power output is improved, but volume increases
Solution Approach 1:
The patent changes the dimensional parameters of the lead exit holes to create an interference fit with the phase leads. This parameter optimization allows for compact sealing that maximizes the space available for active motive material within the given motor volume, thereby improving power density without increasing overall size.
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 design effectively increases power density by maximizing active motive material within a given size, providing a compact, high-power motor that can operate in environments with dust, dirt, and moisture, while minimizing weight and complexity.
Implementation Method 1
utilizing heat shrink tubing and crimped wire barrels for phase leads
Implementation Method 2
As current is running through a given wire winding it generates a local magnetic field which then repels and/or attracts any nearby permanent magnets
Implementation Method 3
As current is running through a given wire winding it generates a local magnetic field which then repels and/or attracts any nearby permanent magnets such as permanent magnet N 112 and permanent magnet S 114 of rotor 104 thereby causing rotor 104 to spin or rotate
Implementation Method 4
utilizing heat shrink tubing and crimped wire barrels for phase leads
Data Source
AI summary
An electric motor configured to maximize active motive material within a given motor size by having one or more phase lead exit holes configured to prevent unwanted outside contaminants from entering the motor, phase leads each having an integral strain relief, and two or more Wye terminations that are not electrically connected to each other.