Electric Motor Wiring Unit for Automated Stator Assembly
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Solution Overview
Problem
Conventional electric motor manufacturing processes are complex and costly due to the need for precise wiring connections between stator segments, which often require manual assembly and result in a non-compact configuration, increasing production time and costs.
Innovation Solution
A wiring unit with a carrier part made from insulating material, featuring multiple wiring elements arranged in a compact configuration using laser welding or alternative methods like brazing or ultrasonic welding, allows for automated assembly and reduced production complexity by integrating wiring elements with a carrier part, enabling efficient electrical connections between stator segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional manual wiring assembly is used, then wiring connections between stator segments can be achieved, but production time and costs increase due to complex manual assembly processes
Solution Approach 1:
The patent combines multiple wiring elements and their supporting structure into a single integrated wiring unit. This wiring unit includes a carrier component with multiple wiring elements arranged in a specific pattern, allowing automated assembly as one complete unit rather than individual manual connections, thereby reducing production time while maintaining manufacturing ease
Solution Approach 2:
The wiring elements are pre-arranged in a predetermined pattern on the carrier component during manufacturing. This preliminary arrangement allows the entire wiring unit to be assembled automatically in one operation, eliminating time-consuming manual wiring processes while keeping the manufacturing process simple and repeatable
2Reliability
If conventional wiring connections are used, then electrical connections between coils can be established, but device complexity increases due to multiple separate wiring components
Solution Approach 1:
Multiple wiring elements that would otherwise be separate components are merged into a single wiring unit with a common carrier. This integration reduces device complexity by eliminating the need to handle and assemble multiple separate wiring components, while maintaining reliable electrical connections through the structured arrangement of wiring elements on the carrier
3Ease of manufacture
If wiring elements are arranged in a non-compact configuration, then assembly may be simpler, but space utilization decreases and mechanical stability is reduced
Solution Approach 1:
The wiring elements are arranged in a compact, organized pattern on the carrier component, optimizing space utilization within the stator assembly. The structured layout maintains ease of assembly through standardized positioning while achieving a compact configuration that improves mechanical stability and reduces overall wiring unit volume
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 solution simplifies the production of electric motors by reducing production outlay, enabling cost-effective and stable manufacturing with automated assembly and a compact wiring configuration, enhancing electrical insulation and mechanical stability.
Implementation Method 1
connected to one another in a star connection, in particular in a star connection with a star connection point, with the aid of a wiring unit (1, 100), in particular with the aid of a substantially annular wiring unit (1, 100), at least three first wiring elements (30, 90) being provided, in particular, each of the first wiring elements (30, 90) having two, in particular precisely two, contacting regions (31, 32; 91, 92) which are set apart from one another, and a connection region (33; 94) connected to the contacting regions (31, 32; 91, 92), in particular so that the connection region (33; 94) is situated between the contacting regions (31, 32; 91, 92), the contacting regions (31, 32; 91, 92), in particular all contacting regions (31, 32; 91, 92), of each first wiring element (30, 90) being connected to one of the coil connections (5, 6) at a connection point in each case, in particular electrically connected, in particular integrally connected with the aid of laser welding
Implementation Method 2
the wiring unit having a carrier part, in particular a substantially annular carrier part, in particular a carrier part made from an insulating material, for the accommodation of multiple, in particular at least four, wiring elements which are set apart from one another
Data Source
AI summary
An electric motor includes a rotor and a stator, the stator having multiple coils, each coil having two coil connections, the stator having multiple stator segments, and each stator segment having precisely one coil, the coils being connected to one another by a wiring unit having a carrier part, for accommodating multiple wiring elements set apart from one another.