Spring Clamp Sensor Holder for Electric Machine Conductor
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Solution Overview
Problem
There is a need to optimize the arrangement of temperature sensors on electrical conductors of electric machines for reliable temperature detection, especially in high-temperature environments like starter generators, where precise temperature measurement is crucial for secure operation.
Innovation Solution
A spring clamp with a sensor holder and spring arm is designed to securely fasten a temperature sensor to an electrical conductor, using a self-adjusting mechanism that compensates for conductor variations, ensuring the sensor is fixed and pressed onto the conductor for effective temperature detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a temperature sensor is attached to an electrical conductor using conventional methods, then the sensor can detect temperature, but the sensor positioning is not secure and may shift under thermal expansion or mechanical stress
Solution Approach 1:
The patent employs a dynamic spring clamp mechanism that automatically adjusts to conductor dimensional changes. The spring-loaded arms provide continuous contact pressure that adapts to thermal expansion and contraction of the conductor, maintaining secure sensor positioning without requiring complex fixed mounting structures.
Solution Approach 2:
The spring clamp mechanism is self-adjusting and requires no external actuation. The spring force automatically compensates for conductor movement and dimensional changes, providing self-regulating pressure that secures the sensor in place without additional control systems or manual intervention.
2Reliability
If the spring clamp exerts strong clamping force to secure the sensor, then positioning stability improves, but the conductor may be damaged or deformed
Solution Approach 1:
The spring clamp uses elastic deformation of the spring arms to provide clamping force. The material and geometry of the spring arms are designed to limit maximum clamping force to values that secure the sensor without exceeding the conductor's yield strength, preventing damage while maintaining fixation security.
Solution Approach 2:
The spring clamp employs flexible spring arms that can deform elastically to accommodate conductor dimensional changes. This flexibility allows the clamp to maintain secure sensor positioning through elastic compliance rather than rigid constraint, avoiding stress concentration and potential conductor damage.
3Ease of manufacture
If the spring clamp design is simplified for easy manufacturing, then manufacturing cost decreases, but the ability to maintain secure sensor positioning under thermal stress deteriorates
Solution Approach 1:
The spring clamp is designed as a segmented structure with distinct spring arms and a sensor holder component. This segmentation allows each part to be manufactured using simple processes while the assembled structure provides the complex functionality of adaptive clamping and secure sensor positioning under thermal stress.
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 spring clamp provides a positionally secure and simple method to attach a temperature sensor to an electrical conductor, ensuring reliable temperature detection and secure positioning, even under fluctuating conditions, thereby enhancing the operational safety of electric machines.
Implementation Method 1
a spring force is exerted by way of the spring arm such that a sensor which is and/or may be arranged in the sensor holder is fixed in the sensor holder by way of the press-on tab, and the sensor holder is pressed onto the electrical conductor
Implementation Method 2
the first spring leg and the second spring leg are arranged and/or formed with respect to one another in such a way that a receiving opening for receiving an electrical conductor is formed between a free first end portion of the first spring leg and a free second end portion of the second spring leg, and the conductor is clamped between the first end portion and the second end portion
Data Source
AI summary
A spring clamp for plugging onto an electrical conductor of an electric machine, having a first spring leg and a second spring leg adjoining the first spring leg. The spring legs are arranged and/or formed with respect to one another in such a way that a receiving opening for receiving the electrical conductor is formed between a free first end portion of the first spring leg and a free second end portion of the second spring leg, and the conductor is clamped between the first end portion and the second end portion. The second spring leg has a sensor holder and a spring arm with a press-on tab, a spring force is exerted by way of the spring arm such that a sensor arranged in the sensor holder is fixed in the sensor holder by way of the press-on tab, and the sensor holder is pressed onto the electrical conductor.