Electric Machine Power Connection Unit Segmentation
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Solution Overview
Problem
Existing electric machines with power connection units face challenges in handling and accessing the terminal conductors due to the complexity of the plastic carrying part, which hinders efficient connection and welding processes.
Innovation Solution
The power connection unit is designed as a plastic composite element with terminal conductors embedded in a plastic shell, allowing for better spatial access and flexibility in positioning, with separate structural components that can be securely fastened to the stator using positive engagement and sealing to protect against external influences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminal conductors are inserted in a common tub-shaped plastic carrying part and sealed, then the power connection unit is protected and integrated, but the handling and spatial access for welding tools becomes difficult
Solution Approach 1:
The plastic carrying part is divided into multiple separate plastic shells, each accommodating individual terminal conductors. This segmentation allows welding tools to access each terminal conductor independently from different directions, resolving the spatial access problem while maintaining protection through individual encapsulation.
Solution Approach 2:
The terminal conductors are arranged in a distributed spatial configuration rather than being bundled together in a single tub-shaped structure. This dimensional redistribution provides multiple access paths for welding tools around the stator circumference, eliminating the handling difficulties caused by the compact sealed structure.
2Ease of operation
If terminal conductors are embedded in a plastic shell to be spaced apart, then spatial access is improved, but the structural integration and positioning precision becomes more complex
Solution Approach 1:
The terminal conductors are pre-positioned and fixed within the plastic shells before the actual connection process. This preliminary positioning ensures precise spatial arrangement is achieved during manufacturing, while the modular plastic shell structure maintains ease of access for subsequent connection operations.
Solution Approach 2:
The plastic shells serve as intermediary structures that hold the terminal conductors in precise positions. These shells act as positioning fixtures during manufacturing, ensuring accurate spatial arrangement without requiring complex direct positioning mechanisms for the conductors themselves.
3Adaptability or versatility
If power connection unit is provided as a separate structural component, then flexibility in positioning is improved, but the fastening and securing process becomes more complex
Solution Approach 1:
The power connection unit is segmented into separate plastic shells that can be independently positioned and fastened. This segmentation provides positioning flexibility while simplifying the fastening process, as each shell can be secured independently rather than requiring complex fastening for a single integrated structure.
Solution Approach 2:
The plastic shells provide a flexible yet structurally sound housing for the terminal conductors. These shells can be easily positioned at different locations on the stator and secured using simple fastening methods, achieving both positioning flexibility and structural integrity without complex fastening mechanisms.
Data Source
AI summary
An electric machine has a stator which carries a polyphase coil winding, wherein coil ends are connected in a predetermined manner to a plurality of electric connection conductors. The electric machine comprises a power connection unit having a plurality of terminal conductors which are constructed separate from the connection conductors and which by a first end portion are bondingly connected or connectable to the connection conductors and by a second end portion are connected or connectable to the electrical energy source. The power connection unit is constructed as a plastic composite element, in which the terminal conductors are embedded at least over a portion of their length in a plastic shell so as to be spaced apart from one another, and wherein first end portions of the terminal conductors project out of the plastic shell.