Neutral Wire Fixing Structure for Stator Temperature Sensor Stability
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Solution Overview
Problem
The existing fixing structure for a neutral wire and temperature sensor in stator coils faces challenges in securely attaching the temperature sensor due to alignment errors and vibrations, leading to reduced force and increased displacement, which affects the accuracy of temperature measurement and potential damage from resin molding and vibration.
Innovation Solution
The proposed fixing structure incorporates protruding portions from the neutral wire that face each other or a predetermined portion, allowing for increased area and force of attachment, with the temperature sensor sandwiched between these protrusions, and includes configurations where the temperature sensing element is positioned within the current path for accurate temperature measurement, and the neutral wire is arranged with inclined portions to prevent lead wire breakage and improve visibility during inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the temperature sensor is fixed using a conventional structure with limited sandwiching area, then the device complexity is low, but the fixing force is insufficient and the temperature sensor experiences displacement due to vibrations
Solution Approach 1:
The neutral wire is segmented into multiple protruding portions that protrude in different directions, creating multiple sandwiching points for the temperature sensor. This segmentation increases the total fixing force by distributing the clamping action across multiple contact points while maintaining a relatively simple overall structure.
Solution Approach 2:
The neutral wire is configured to protrude in multiple spatial dimensions (radial and axial directions) rather than a single direction. This multi-dimensional protrusion creates a more comprehensive sandwiching effect on the temperature sensor, increasing fixing force through three-dimensional constraint.
2Device complexity
If the neutral wire is bent into a U-shape to fix the temperature sensor, then the structure is simple, but the alignment errors cause reduced fixing force and increased displacement
Solution Approach 1:
Instead of relying on a single U-shaped bend, the neutral wire is divided into multiple protruding segments that can independently contact the temperature sensor. This segmentation compensates for alignment errors by providing multiple contact points, ensuring that at least some protruding portions maintain proper contact pressure even if individual segments are misaligned.
Solution Approach 2:
The design allows for adjustment of the protruding portions' dimensions, shapes, and spatial arrangements to optimize fixing performance. By varying these parameters, the structure can accommodate alignment tolerances while maintaining reliable fixing force across different assembly conditions.
3Temperature
If the temperature sensor is positioned away from the current path, then the sensor is protected from heat, but the temperature measurement accuracy decreases
Solution Approach 1:
The protruding portions of the neutral wire act as intermediaries that conduct heat from the current path to the temperature sensor. By positioning the sensor near the protruding portions rather than directly in the current path, the wire itself serves as a thermal conduit, allowing accurate measurement of the neutral point temperature while reducing direct thermal exposure to the sensor.
Solution Approach 2:
The protruding portions are positioned to pre-establish optimal thermal contact with the temperature sensor before operation. This preliminary configuration ensures that the sensor is thermally coupled to the neutral wire at the measurement point while maintaining spatial separation from the high-current path, balancing measurement accuracy with thermal protection.
4Area of stationary object
If the lead wire is arranged near the stator core corners, then the space utilization is high, but the lead wire is susceptible to breakage from vibrations and resin molding pressure
Solution Approach 1:
The inclined portions of the neutral wire serve as intermediary support structures that redirect and distribute the mechanical stresses from resin molding and vibrations away from the lead wire. By positioning the lead wire exit through these inclined portions, the wire is protected from direct contact with high-stress zones at the stator core corners while still achieving compact spatial arrangement.
Solution Approach 2:
The inclined portions are designed with specific angles and dimensions that optimize the redistribution of mechanical loads. By adjusting these geometric parameters, the lead wire pathway is configured to minimize exposure to damaging forces while maintaining efficient space utilization within the stator assembly.
Data Source
AI summary
A fixing structure for fixing a neutral wire and a temperature sensor fixes the neutral wire forming a neutral point of a stator coil and the temperature sensor. The fixing structure has a plurality of protruding portions that protrude from the neutral wire in a direction away from a current path in the neutral wire during energization and are opposed to each other. The temperature sensor is sandwiched between a plurality of protruding portions facing each other.