Polymer-Coated Electric Machine Component for Cable Protection
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Solution Overview
Problem
Electrical machines, such as motors, face challenges with cable management and protection due to sharp edges and complex assembly processes, leading to potential damage and increased costs, particularly in areas like terminal boards and stator windings where cables are manually routed and fixed.
Innovation Solution
A polymer layer comprising hardened plastic adhesive is applied to flat areas within electrical machines, forming a network structure that adheres without additional adhesives, protecting cables from damage and spanning sharp edges, and can be applied using thermoplastic hot melt adhesive in a fully automated process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual cable routing and fixing methods are used in electrical machines, then cables can be installed and secured, but the assembly process becomes time-consuming and costly
Solution Approach 1:
The patent replaces manual mechanical cable routing and fixing operations with an automated polymer coating application system. The polymer layer is applied automatically to cover sharp edges and secure cables, eliminating the need for manual intervention in these tasks.
Solution Approach 2:
The polymer layer is applied in advance during the manufacturing process to cover sharp edges and provide cable routing paths before cables are installed. This preliminary preparation simplifies subsequent cable installation and eliminates the need for separate cable securing operations.
2Reliability
If manual cable fixing using grid bands is used, then cables can be secured to the winding head, but the process is time-consuming and costly
Solution Approach 1:
The patent replaces manual cable fixing with grid bands with automated polymer coating application. The polymer layer automatically secures cables to the winding head, eliminating manual operations while maintaining reliable cable fixation.
3Ease of manufacture
If sharp edges are present on cast metal housings and stator laminations, then manufacturing is simplified, but cable insulation and wires are at risk of damage
Solution Approach 1:
The patent converts the harmful sharp edges into a beneficial feature by using them as a substrate for polymer coating application. The polymer layer is applied over the sharp edges, transforming the hazardous feature into a protected surface that actually enhances cable protection while maintaining the manufacturing simplicity of cast metal and laminated structures.
Solution Approach 2:
The polymer layer is applied in advance to cover sharp edges before cables are installed or routed near these areas. This creates a protective cushion that prevents damage to cable insulation and wires, eliminating the need for subsequent deburring or edge protection operations.
4Ease of operation
If openings are made in the casing for wire routing, then cable access is enabled, but contamination can pass through affecting connections
Solution Approach 1:
The polymer layer serves multiple functions simultaneously: it provides cable routing paths through the openings, seals the openings to prevent contamination, and protects cables from sharp edges. This multi-functional approach eliminates the need for separate sealing and routing operations.
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 effectively protects cables from mechanical stress and damage, simplifies the assembly process, and reduces costs by providing a durable, pore-free adhesive layer that covers sharp edges and secures cables, enhancing operational safety and efficiency.
Implementation Method 1
a thread of thermoplastic hot melt adhesive is produced by means of a nozzle
Implementation Method 2
a thread of thermoplastic hot melt adhesive is produced by means of a nozzle, and during production the nozzle is moved in such a way that the thread is applied layer by layer
Implementation Method 3
the polymer layer comprises cured plastic adhesive and adheres to the planar area
Data Source
Figure 1
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AI summary
The invention relates to a component for an electric machine. The component comprises at least one polymer layer which is adhered to at least one flat region of the component, wherein the polymer layer comprises cured plastic adhesive, and at least one electric line runs on the at least one flat region at least when the component is installed into the electric machine.