Electric Machine Sensor Anchor for Winding Protection
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Solution Overview
Problem
Current thermal management systems for electric machines in electrified vehicles face challenges in effectively monitoring and managing temperature, particularly in high-power traction batteries and electric machines, which can lead to inefficiencies and potential damage due to inadequate temperature sensing and securing mechanisms.
Innovation Solution
A temperature sensor assembly with an elongated housing, screw threads, and resilient tabs is designed to securely attach to stator windings, providing reliable temperature monitoring by compressing tabs and rotating the assembly to engage screw threads between axially spaced windings, ensuring stable and flexible attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a temperature sensor assembly is attached to stator windings using conventional methods, then temperature monitoring can be achieved, but the attachment may be insecure or damage the windings due to lack of flexible securing mechanisms
Solution Approach 1:
The patent uses resilient tabs made of flexible material that can deform and conform to the stator windings without causing damage. These tabs provide a secure attachment while accommodating the flexible nature of the windings, preventing both detachment and winding damage through their elastic properties
Solution Approach 2:
The resilient tabs act as an intermediary element between the temperature sensor assembly and the stator windings. Instead of directly fastening the sensor to the windings (which could cause damage), the tabs provide a compliant interface that secures the sensor while protecting the windings from mechanical stress
2Strength
If screw threads are used to secure the temperature sensor assembly, then firm attachment is achieved, but installation complexity increases due to the need for precise threading between axially spaced windings
Solution Approach 1:
The securing mechanism is segmented into multiple functional elements: resilient tabs for initial positioning and flexible securing, and screw threads for final firm attachment. This segmentation allows each element to perform its specific function optimally while simplifying the overall installation process compared to using a single complex fastening system
3Reliability
If the temperature sensor assembly is designed with resilient tabs and screw threads, then secure and flexible attachment is achieved, but manufacturing complexity increases
Solution Approach 1:
The resilient tabs and screw threads are merged into a single integrated anchor portion of the temperature sensor assembly housing. This combination allows both flexible securing and firm attachment capabilities to be achieved through one manufacturing process, reducing the number of separate components and simplifying production compared to using separate fastening elements
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 enhances temperature monitoring and management, improving the reliability and efficiency of electric machines by providing accurate temperature data and secure attachment, thus preventing damage from overheating.
Implementation Method 1
opposing tabs extending from the outer perimeter of the elongated housing proximate the screw thread. The tabs may be resiliently flexible relative to the elongated housing
Data Source
AI summary
An electric machine for an electrified vehicle includes a stator and a temperature sensor assembly. The temperature sensor assembly includes an elongated housing having an anchor portion disposed within the windings. The anchor portion includes a screw thread extending about an outer perimeter of the elongated housing, resilient tabs extending from the outer perimeter, and a temperature sensor housed within the anchor portion of the elongated housing.