Motor Coil Temperature Sensor Mounting With Bus Bar Spring
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Solution Overview
Problem
Existing motor designs that incorporate temperature sensors for measuring stator or coil temperatures often require complex and time-consuming processes for attaching springs that press the temperature sensors against the coils.
Innovation Solution
A motor design that simplifies the attachment process of a spring pressing a temperature sensor against a coil by fixing the spring to a bus bar, allowing simultaneous attachment with the bus bar to the stator, thereby streamlining the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the spring is attached separately to press the temperature sensor against the coil, then the temperature measurement function is achieved, but the attachment process becomes complex and time-consuming
Solution Approach 1:
The spring is integrated with the bus bar to form a unified component. The bus bar serves dual functions: electrical connection and mechanical support for the spring. This merging eliminates the need for separate spring attachment steps, reducing process complexity while maintaining the temperature measurement function.
Solution Approach 2:
The bus bar is designed to perform multiple functions: it provides electrical connection to the coil and simultaneously serves as the mounting structure for the spring. This multi-functionality reduces the number of components and simplifies the overall assembly process while ensuring accurate temperature measurement through the spring-loaded temperature sensor.
2Measurement precision
If the spring is attached separately to press the temperature sensor against the coil, then the temperature measurement function is achieved, but the assembly time increases
Solution Approach 1:
The spring and bus bar are combined into a single integrated component. This allows the spring to be attached simultaneously with the bus bar during the same assembly operation, eliminating separate attachment steps and reducing overall assembly time while maintaining accurate temperature measurement.
Solution Approach 2:
The spring is pre-integrated with the bus bar structure, so that when the bus bar is installed, the spring is already in position and ready to press the temperature sensor against the coil. This preliminary integration eliminates the need for subsequent spring attachment operations, reducing assembly time.
3Measurement precision
If the spring is attached separately to press the temperature sensor against the coil, then the temperature measurement function is achieved, but automation of the attachment process becomes difficult
Solution Approach 1:
The spring is integrated with the bus bar to form a single component that can be handled and installed as one unit. This integration enables automation equipment to attach both the bus bar and spring simultaneously using standard handling fixtures, making the process suitable for automated assembly lines while maintaining accurate temperature measurement.
Solution Approach 2:
The integrated bus bar-spring structure is designed to be self-contained, allowing automation equipment to handle and install the complete assembly in one operation. The spring automatically assumes its pressing function once the bus bar is positioned, eliminating the need for separate spring attachment steps that would be difficult to automate.
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 design simplifies the attachment process of the spring, allowing for efficient and automated assembly, ensuring accurate temperature measurement and reducing the risk of human error.
Implementation Method 1
a temperature sensor in contact with the coil... in contact with the coil means in thermal contact with the coil
Implementation Method 2
an elastic member is disposed between the temperature sensor and the inner face of the housing. The elastic member presses the temperature sensor against the coil
Data Source
Figure 1~2
Figure 3
AI summary
A motor (2) includes a coil (10) that is wound on a stator (3), a bus bar (31) that is disposed facing the coil (10) and connected to the coil (10), a temperature sensor (20) that is disposed between the coil (10) and the bus bar (31), and that is also in contact with the coil (10), and a spring (35) that is disposed between the bus bar (31; 131) and the temperature sensor (20), and that presses the temperature sensor (20) against the coil (10).