Rotating Interconnection Element for Electric Machine Winding Assembly
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Solution Overview
Problem
The contact-connection of multiple projecting shaped-bar ends in electric motor windings is challenging due to positional deviations caused by tolerances, leading to increased friction and abrasion during assembly, and requires larger space and obstruction detection.
Innovation Solution
An interconnection device with an annular interconnection element featuring insertion and contact-making sections, allowing for relative movement to guide shaped-bar ends into position, reducing distance and preventing abrasion, facilitated by a guide apparatus and stud section, enabling simultaneous insertion and contact connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If shaped-bar ends are inserted into holes in the interconnection unit to accommodate positional deviations, then the interconnection can be achieved despite tolerances, but the sharp cut edges of the shaped-bar ends engage with lead-in chamfers causing increased friction forces and abrasion
Solution Approach 1:
The interconnection element is first fitted to the stator in a preliminary position where the openings have larger insertion sections that can accommodate positional deviations of shaped-bar ends. After fitting, the interconnection element is rotated to bring the shaped-bar ends into contact with the contact bars for welding. This preliminary positioning avoids the need for lead-in chamfers and reduces friction and abrasion during assembly.
Solution Approach 2:
The interconnection element is designed to be rotatable relative to the stator, transforming from a static to a dynamic component. This rotation allows the system to adapt to positional deviations of shaped-bar ends while maintaining proper alignment for contact connection, thereby reducing friction and abrasion forces during the assembly process.
2Ease of operation
If lead-in chamfers are provided on holes to facilitate insertion of shaped-bar ends, then insertion is easier, but the assembly process requires larger space and obstruction detection
Solution Approach 1:
The interconnection element is pre-positioned on the stator with openings that have larger insertion sections capable of accommodating positional deviations. This preliminary positioning eliminates the need for lead-in chamfers, simplifying the insertion process while reducing assembly space requirements and eliminating the need for obstruction detection.
3Manufacturing precision
If the interconnection unit is positioned directly for welding, then contact connection can be achieved, but positional tolerances of shaped-bar ends make simultaneous insertion difficult
Solution Approach 1:
The opening in the interconnection element is segmented into two functional sections: a larger insertion section for accommodating positional deviations and a smaller contact-making section for precise contact connection. This segmentation allows the assembly process to first accommodate tolerances and then achieve precise contact, making manufacturing easier while maintaining precision.
Solution Approach 2:
The interconnection element is first positioned in a preliminary location where the larger insertion section accommodates shaped-bar ends with positional deviations. After all shaped-bar ends are inserted, the interconnection element is rotated to bring the contact bars into contact with the shaped-bar ends for welding. This two-step process simplifies assembly while ensuring precise contact connection.
Data Source
AI summary
An interconnection device for an electric machine, in particular for an electric machine for a motor vehicle, is provided for interconnecting shaped-bar ends of a winding, in particular of a stator winding. The interconnection device has an interconnection element, which has one or more openings for the insertion of at least one shaped-bar end, wherein the one or more openings each have an insertion section and a contact-making section adjoining the insertion section, which sections are designed such that the at least one shaped-bar end can be inserted into the insertion section and, in the case of a relative movement between the opening and the inserted shaped-bar end, the inserted shaped-bar end reaches the contact-making section and the spacing between the at least one shaped-bar end and a contact is reduced by way of being guiding through the contact-making section.