Identical Segmented Contact Ring for Compact Stator Assembly
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Solution Overview
Problem
Existing contact rings for stators in electronically commutated electric motors are complex to manufacture and assemble, requiring differentiation and simultaneous assembly of non-identical elements, which complicates the process and occupies more space.
Innovation Solution
A multi-part contact ring formed from identical, partially ring-shaped metallic elements with offset configurations, allowing for simpler assembly and a compact design by overlapping without touching, and can be arranged in various positions to facilitate easier installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If contact rings are designed with non-identical elements to connect terminals to stator winding, then the electrical connection function is achieved, but the manufacturing and assembly complexity increases
Solution Approach 1:
The contact ring is divided into multiple individual contact flags, each consisting of identical metallic elements that can be manufactured separately and then assembled. This segmentation allows for standardized production of identical elements while maintaining the functional complexity of the overall contact ring structure.
Solution Approach 2:
All metallic elements in the contact ring are designed to be identical in shape, size, and material properties. Each element has the same L-shaped configuration with a bend, allowing them to be manufactured using the same process and interchangeable during assembly, thereby reducing manufacturing complexity despite the multi-part structure.
2Productivity
If multiple non-identical contact ring elements are used, then the electrical connection is established, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The metallic elements are pre-formed with the correct L-shape and bend configuration during manufacturing. This preliminary action ensures that during assembly, the elements can be directly positioned and connected without requiring on-site shaping or complex manipulation, thereby speeding up the assembly process.
Solution Approach 2:
Since all metallic elements are identical, the same assembly procedure can be repeated for each element, reducing the skill level required and enabling standardized assembly processes. This homogeneity allows workers to assemble multiple elements using the same technique, improving overall assembly efficiency.
3Volume of moving object
If contact ring elements are positioned in overlapping configurations, then the space requirement is reduced, but the risk of electrical short circuit increases
Solution Approach 1:
An insulating element is introduced as an intermediary component between the overlapping metallic elements of adjacent contact flags. This insulating element physically separates the conductive parts while allowing the contact flags to maintain their compact overlapping arrangement, thus preserving both space efficiency and electrical insulation.
Solution Approach 2:
The contact ring structure combines metallic elements for electrical conduction with insulating elements for electrical isolation. This composite material approach allows the overlapping configuration to maintain both its compact geometry and its electrical safety by using materials with complementary properties in the same structure.
Data Source
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AI summary
The invention relates to a contact ring 10 for arrangement on a stator 40 of an electronically commutated electric motor 50, wherein the contact ring 10 is formed from at least two pairs of identical, partially annular, metallic elements 2n, 2g. Each of the pairs is connected to a terminal 20U, 20V, 20W for connection to a voltage source. One of the two elements 2n of a pair 2n, 2g extends from the terminal 20U, 20V, 20W in a first normal position in a first circumferential direction of the stator 40, and the other element 2g extends from the terminal 20U, 20V, 20W in a second position, reversed relative to the first normal position, in a second circumferential direction of the stator 40. The individual elements have a bend 8, so that two facing elements 2n, 2g of the contact ring 10 of two adjacent terminals 20U, 20V, 20W overlap in the area of the bend without touching each other.