Radial Thermistor Assembly for Secure Stator Core Mounting
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Solution Overview
Problem
Current methods for mounting thermistors to stator cores in electric machines are labor-intensive, result in inadequate bonding, and lead to inconsistent placement and sensing issues, particularly due to the thermistor loosening before varnish application.
Innovation Solution
A radially insertable thermistor assembly with a thermistor housing featuring radially outwardly extending elements that grip stator windings, combined with a sensing element and filler material like epoxy, ensures secure and consistent placement within the void between stator windings, using a clip member to support sensing cables and prevent deep insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current mounting techniques (harness, heat shrink tubing, lacing) are used to secure the thermistor to the stator, then the thermistor can be attached to the stator, but the bonding is inadequate and the placement is inconsistent
Solution Approach 1:
The thermistor is pre-positioned in the void between stator windings before the stator is assembled and before varnish application. The radially outwardly extending elements are already in place to grip the windings, ensuring consistent placement and strong bonding before final assembly. This preliminary positioning eliminates the inconsistency and bonding issues of post-assembly mounting methods.
Solution Approach 2:
The radially outwardly extending elements act as an intermediary mechanical feature that bridges the thermistor housing and the stator windings. These elements extend through the void and grip the windings directly, providing a reliable mechanical bond that is superior to harnesses or heat shrink tubing while ensuring consistent placement.
2Reliability
If the thermistor is mounted using traditional methods, then it can be attached to the stator, but it may loosen before varnish application resulting in inadequate sensing
Solution Approach 1:
The thermistor is securely positioned in the void between stator windings using the radially outwardly extending elements before varnish application and final assembly. This preliminary secure mounting prevents the thermistor from loosening during the assembly process, ensuring continuous reliable sensing throughout the assembly sequence.
Solution Approach 2:
The radially outwardly extending elements automatically grip the stator windings when the thermistor housing is inserted into the void, providing self-securing mounting without requiring additional fasteners or adhesives during assembly. This self-service mounting mechanism ensures the thermistor remains stable throughout the assembly process.
3Reliability
If a radially insertable thermistor assembly with outwardly extending elements is used, then secure and consistent placement is achieved, but the device complexity increases
Solution Approach 1:
The thermistor housing is merged with the radially outwardly extending elements to form an integrated assembly. The extending elements are built into the housing structure itself, eliminating the need for separate mounting components and reducing overall device complexity while maintaining secure mounting.
Solution Approach 2:
The radially outwardly extending elements serve multiple functions: they provide mechanical grip on the stator windings, position the thermistor housing correctly in the void, and prevent over-insertion. This multi-functionality reduces the need for additional components, offsetting the increased complexity of the housing structure.
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
The solution provides a secure, consistent, and reliable mounting of thermistors to stator cores, enhancing temperature sensing accuracy and durability by ensuring a strong bond and stable placement.
Implementation Method 1
radially outwardly extending elements that extend through a void between two adjacent stator windings and being operable to connect to one of the stator and the plurality of stator windings
Implementation Method 2
combined with a sensing element and filler material like epoxy, ensures secure and consistent placement within the void between stator windings
Data Source
AI summary
A radially insertable thermistor assembly for installation into a stator having a plurality of stator windings. The radially insertable thermistor assembly includes a thermistor housing having one or more radially outwardly extending elements that extend through a void between two adjacent stator windings and being operable to connect to one of the stator and the plurality of stator windings, and a sensing element arranged at the thermistor housing.