Overmolded Distributed Connection Ring for Stator Insulation
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Solution Overview
Problem
Existing electric machine stator assemblies face challenges in securely integrating neutral connections and jumping winding connections while ensuring adequate insulation and efficient packaging within limited space.
Innovation Solution
A distributed connection assembly is introduced, featuring an overmolded neutral connector and circumferentially spaced overmolded couplers made of polymeric and conductive materials, respectively, which are arcuately shaped to minimize space and weight, and can include a nested configuration for further compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If traditional connection methods are used for neutral connections and jumping winding connections, then adequate insulation can be achieved, but the assembly occupies excessive space and has increased complexity
Solution Approach 1:
The patent combines neutral connections and jumping winding connections into a single integrated overmolded assembly. The neutral connector and couplers are molded together as one unit, eliminating the need for separate insulation components and reducing overall assembly volume while maintaining adequate insulation through the overmolded material.
Solution Approach 2:
The overmolded couplers are nested within the overmolded neutral connector assembly. The couplers are positioned inside the neutral connector's molded structure, creating a compact nested configuration that minimizes space occupation while keeping all connection elements properly insulated and organized.
2Weight of stationary object
If separate connection components are used for neutral connections and jumping winding connections, then ease of manufacture can be achieved, but the assembly weight and complexity increase
Solution Approach 1:
Multiple separate connection components (neutral connector, couplers, insulation elements) are merged into a single overmolded assembly. This integration reduces the total number of parts and overall weight, while the molding process itself handles the complexity of creating the integrated structure in one manufacturing step.
3Volume of stationary object
If compact packaging is implemented for connection assemblies, then space optimization is achieved, but insulation and securing of jumping winding connections may be compromised
Solution Approach 1:
The compact packaging is achieved through nested arrangement where couplers are positioned inside the neutral connector assembly. This nested configuration maintains adequate insulation distances and secures jumping winding connections properly while minimizing the overall volume occupied by the connection assembly.
Data Source
AI summary
A distributed connection ring assembly can be used in a stator assembly and can integrate a neutral connector and jumping winding connections in an overmolded assembly for insulation. The stator assembly including a stator core defining a plurality of slots spaced apart from each other, a plurality of bar conductors disposed in each of the slots, and a distributed connection ring assembly secured to the jumping winding connections. The distributed connection ring assembly includes an overmolded neutral connector. The distributed connection ring assembly also includes a plurality of overmolded couplers circumferentially spaced apart from one another. The overmolded couplers are coupled to the overmolded neutral connector. Each of the plurality of overmolded couplers includes a support body and a plurality of stator conductors partially disposed inside the support body. The stator conductors are electrically connected to the jumping winding connections.