Electric Motor Wiring Unit with Insulated Carrier
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Solution Overview
Problem
Existing electric motor designs face challenges in reducing manufacturing effort, cost, and complexity while maintaining stability and efficiency in connecting coil windings, particularly in synchronous motors with individual stator tooth segments.
Innovation Solution
An electric motor with an interconnection unit featuring a disc-shaped carrier part made of insulating material, using conductive interconnection elements made of metal or sheet copper, which are securely fastened to the carrier part through rivet pins and ultrasonic welding, allowing for a compact and stable connection of coil connections in a star configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional wiring methods with multiple separate connection components are used, then electrical connections can be established, but manufacturing complexity and assembly effort increase
Solution Approach 1:
The patent combines multiple separate connection components (support structure, connection elements, and wiring) into a single integrated wiring unit that is pre-assembled and pre-tested. This merging reduces manufacturing complexity by allowing the entire wiring assembly to be produced as one module and then installed as a single unit, eliminating the need for complex on-site assembly of multiple separate components.
Solution Approach 2:
The wiring unit is pre-assembled and pre-tested in a controlled manufacturing environment before being installed in the electric motor. This preliminary action ensures that all electrical connections are verified before installation, reducing the need for complex on-site testing and adjustment, thereby simplifying both manufacturing and installation processes.
2Reliability
If coil terminals are connected using conventional interconnection methods, then electrical connections are established, but production stability and connection reliability decrease
Solution Approach 1:
The wiring unit is segmented into distinct functional modules: a support structure for mechanical stability, connection elements for electrical connectivity, and insulating components for electrical isolation. This segmentation allows each module to be optimized and manufactured separately with high precision, then assembled into a reliable integrated unit that improves both connection stability and production consistency.
Solution Approach 2:
The patent employs specific material parameter changes, using conductive materials for connection elements and insulating materials for isolation components. The support structure uses materials with appropriate mechanical properties to ensure stable positioning. These parameter optimizations ensure reliable electrical connections while maintaining production stability across manufacturing batches.
3Productivity
If manual wiring and connection processes are used, then flexibility in assembly is maintained, but manufacturing cost and time increase
Solution Approach 1:
The wiring unit is pre-assembled and pre-tested in a controlled manufacturing environment before being installed in the electric motor. This preliminary action ensures that all electrical connections are verified before installation, reducing the need for complex on-site testing and adjustment, thereby simplifying both manufacturing and installation processes.
Solution Approach 2:
The wiring unit is designed as a self-contained module with built-in mechanical and electrical connection features that enable automated assembly. The integrated design allows the unit to be installed as a single component without requiring manual wiring operations, thereby increasing manufacturing efficiency while maintaining assembly simplicity through standardized interfaces.
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 enables a more reliable, cost-effective, and simpler production process with improved stability and ease of assembly, facilitating automated production and ensuring secure electrical connections without overheating during welding.
Implementation Method 1
The support part has rivet pins for holding the interconnection elements, in particular wherein the rivet pins are designed to complement the corresponding recesses in order to enable a stable mechanical connection between the support part and the interconnection elements
Implementation Method 2
at least one of the interconnection elements and the support part are connected to one another in a material-fitting manner, in particular wherein the connection is created by means of ultrasonic welding
Implementation Method 3
an essentially annular support part made of insulating material, in particular wherein the support part is produced by means of an injection molding process
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
The invention relates to an electric motor, in particular a permanent magnet synchronous motor, comprising a rotor arranged such that it can rotate about an axis of rotation and comprising a stator, wherein the stator has multiple coils, wherein each coil has two coil connections, in particular wherein the stator has multiple stator segments and each stator segment has exactly one coil, wherein the coils are wired to one another by means of a wiring unit, in particular in a star connection, wherein the wiring unit comprises a carrier part, in particular a substantially annular carrier part, in particular a carrier part formed by an insulating material, for receiving multiple, in particular at least four, spaced-apart wiring elements, in particular wherein the wiring unit is arranged at an axial end of the stator, in particular concentrically to the axis of rotation, wherein, in particular at least three, first wiring elements are provided, wherein each of the first wiring elements has two, in particular exactly two, spaced-apart contacting regions and a connection region connected to the contacting regions, in particular such that the connection region is arranged between the contacting regions, wherein the contacting regions, in particular all the contacting regions, of each first wiring element are each connected to one of the coil connections at a respective connection point, in particular electrically connected, in particular integrally connected by means of laser welding, wherein the region covered by the connection region of one of the first wiring elements in the circumferential and radial direction overlaps with a respective region covered by the connection region of another of the first wiring elements in the circumferential and radial direction, wherein each of the first wiring elements has a respective first securing region for interlocking and/or integral connection to the carrier part.