Multi-Plane Contact Ring for Electric Motor Stator
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Solution Overview
Problem
Existing contact rings for electric motor stators face challenges in efficiently connecting and stabilizing coil wire ends while maintaining compactness and mechanical stability, especially in compact designs where space is limited.
Innovation Solution
A contact ring with three planes, including a first plane with neutral conductors, a second plane made of electrically insulating material, and a third plane with phase conductors, featuring feedthroughs of different diameters to accommodate single and multiple coil wires, with crimped sleeves and welding options for secure connections, and support elements for stability and accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a contact ring uses a compact design with feedthroughs for coil wire connections, then the space required is reduced and mechanical stability is improved, but the complexity of connecting multiple coil wires securely increases
Solution Approach 1:
The contact ring is segmented into multiple functional planes (first plane with neutral conductors, second insulating plane, third plane with phase conductors) and feedthroughs of different diameters (first and second feedthroughs). This segmentation allows different types of connections to be made in different locations, simplifying the overall connection process while maintaining compactness.
Solution Approach 2:
The contact ring serves multiple functions simultaneously: it provides electrical insulation between phases, connects coil wires of different phases, provides mechanical support, and enables both neutral point connections and phase connections through its multi-plane structure with different feedthrough types.
2Ease of operation
If the contact ring uses larger feedthroughs to accommodate multiple coil wires, then connection ease is improved, but the compactness and mechanical stability of the contact ring deteriorates
Solution Approach 1:
Different regions of the contact ring have different properties: the first feedthroughs have smaller diameters optimized for single wire connections, while the second feedthroughs have larger diameters optimized for multiple wire connections. The insulating material provides electrical insulation where needed, while conductive materials provide connectivity where required. This local optimization allows ease of connection without compromising compactness.
3Device complexity
If the contact ring integrates both neutral and phase conductors on the same plane, then device complexity is reduced, but electrical insulation between conductors becomes insufficient
Solution Approach 1:
The contact ring uses a three-dimensional multi-plane structure instead of a single-plane design. The first plane contains neutral conductors, the second plane provides electrical insulation, and the third plane contains phase conductors. This dimensional separation ensures adequate electrical insulation between different types of conductors while maintaining a compact integrated structure.
4Stability of the object's composition
If the contact ring uses axial spacers supported on the stator end face, then mechanical stability is improved, but the accessibility for making connections deteriorates
Solution Approach 1:
The contact ring design allows for adjustable positioning and orientation of the conductors and feedthroughs. The multi-plane structure provides flexibility in how connections are accessed, and the support elements can be configured to provide stability while maintaining accessibility for making wire connections.
Data Source
AI summary
A contact ring for a stator of an electric motor has three planes, i.e. a first plane with at least one first conductor; a second plane made of an electrically insulating material; and a third plane with at least one second conductor, and at least one first and one second feedthrough passing through the second plane. The first feedthrough is smaller than the second feedthrough, and the first feedthrough guides coil wires of one coil and the second feedthrough guides coil wires of at least two coils.