Motor Winding Connector Ring for Automated Stator Lug Joining
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Solution Overview
Problem
The manual process of coupling stator windings to lugs in electric motor manufacturing is slow and expensive, necessitating a more efficient and cost-effective method to simplify this step while maintaining performance and versatility.
Innovation Solution
A stator assembly connector system that integrates laser welding, TIG welding, resistance welding, or brazing, along with U-shaped insulating overlays, to automate the attachment of pre-fabricated connectors to stator windings, using copper material and over-molded bus bars for insulation, suitable for round or rectangular wire windings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual hand-welding process is used to couple wire bundles to lugs, then connection reliability is maintained, but manufacturing productivity is low and cost is high
Solution Approach 1:
The patent replaces manual mechanical welding operations with automated laser welding technology. The laser welding system uses optical energy to melt and fuse the wire bundle to the lug, eliminating the need for manual manipulation and significantly increasing manufacturing productivity while maintaining connection reliability.
Solution Approach 2:
The patent changes the welding process parameters from traditional resistance welding to laser welding, which allows for precise control of welding speed, temperature, and penetration depth. This parameter change enables automated high-speed welding while maintaining consistent connection quality.
2Productivity
If automated laser welding is used to attach connectors to stator windings, then manufacturing productivity increases and cost decreases, but manufacturing precision requirements increase
Solution Approach 1:
The patent incorporates preliminary positioning features directly into the connector design, including positioning pins that engage with corresponding holes in the stator winding. This preliminary action ensures precise alignment before the laser welding process begins, allowing automated high-speed assembly without compromising manufacturing precision.
Solution Approach 2:
The patent introduces positioning pins as intermediary elements between the connector and stator winding. These pins serve as mediators that establish precise geometric relationships and alignment, enabling the automated laser welding system to operate at high speed while maintaining the required manufacturing precision.
3Ease of manufacture
If pre-fabricated connectors are used with automated attachment, then manufacturing cost decreases, but device complexity increases due to additional components
Solution Approach 1:
The patent merges multiple functions into the pre-fabricated connector design, including the electrical connection function, the positioning function (through integrated positioning pins), and the insulation function. By combining these functions into a single integrated component, the overall device complexity is reduced despite the automation benefits, and manufacturing cost decreases due to streamlined assembly.
4Reliability
If insulation overlays are added to prevent electrical discharge, then electrical safety is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent uses composite material construction for the connector assembly, combining conductive materials (for electrical connection) with insulating materials (overlays and coatings). This composite approach provides reliable electrical insulation to prevent discharge while maintaining a relatively simple overall structure, as the insulating materials are applied as thin overlays rather than bulky additional components.
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
Facilitates rapid, automated assembly of stator windings, reduces costs, and allows for versatile torque and power configurations, while minimizing electrical discharge and connector alignment issues.
Implementation Method 1
laser welding
Implementation Method 2
TIG welding
Implementation Method 3
resistance welding
Implementation Method 4
brazing
Data Source
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AI summary
A stator assembly is provided that simplifies the process of coupling the stator windings to the winding lugs. The stator assembly includes a pre-fabricated connector that is attached to the stator via a plurality of stator winding terminations. The pre-fabricated connector includes a plurality of electrically conductive termination coupling members that form conductive pathways between at least a portion of the stator winding terminations and a plurality of bus bars, where each of the bus bars includes a lug. The pre-fabricated connector may also include a second plurality of electrically conductive termination coupling members that form conductive pathways between at least a second portion of the stator winding terminations and a plurality of lugless bus bars. An electrically insulating material is overlaid over portions of the connector ring, thereby preventing contact or partial discharge between the various bus bars.