Axially Stacked Interconnector Frames for Electric Machine Stators

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing interconnectors for electric machine stators are complex and bulky to produce, making them inefficient in manufacturing and assembly, particularly in polyphase systems where precise positioning and insulation are critical.

Innovation Solution

A compact interconnector design featuring ring-shaped frames stacked axially with indexing pins for precise positioning, embedded in electrically insulating material, and support feet for non-contact alignment with the stator, facilitating easier assembly and reduced dimensions for improved manufacturing efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a conventional annular-shaped interconnector with conductive tracks is used, then interconnection functionality is achieved, but the device becomes bulky and complex to produce

Engineering Contradiction:

Improveproduction complexityVSAvoidinterconnector structure

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The interconnector is divided into multiple separate ring-shaped frames (first frame, second frame, third frame) stacked axially on top of each other. Each frame carries tabs for welding coil ends, and the frames are electrically insulated from each other. This segmentation simplifies manufacturing by allowing each frame to be produced independently and then assembled through stacking, reducing production complexity while maintaining interconnection functionality.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If indexing pins are added to the interconnector, then positioning precision relative to the stator is improved, but device complexity increases

Engineering Contradiction:

Improvepositioning precisionVSAvoidinterconnector structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The indexing pins are integrated directly into the ring-shaped frames of the interconnector itself, rather than being separate components. The frames include protrusions that act as indexing pins, which cooperate with guide systems carried by insulators of the stator during assembly. This self-service approach provides precise positioning while minimizing additional complexity, as the indexing feature is built into the existing frame structure.

Inventive Principle:

Principle #25Self-service

3Volume of moving object

If multiple ring-shaped frames are stacked axially, then compactness is improved, but insulation requirements become more critical

Engineering Contradiction:

Improveinterconnector dimensionsVSAvoidelectrical insulation

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

Electrically insulating material is introduced as an intermediary between the stacked ring-shaped frames to prevent electrical contact and ensure proper insulation. The insulating material is embedded within the interconnector structure, allowing the frames to be closely stacked for compactness while maintaining reliable electrical isolation. This intermediary solution enables the compact stacked design without compromising insulation reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 simplifies the manufacturing and assembly of interconnectors by enabling precise positioning and insulation, reducing production complexity and enhancing the compactness of the interconnector, thus improving the efficiency and reliability of polyphase electric machine stators.

Implementation Method 1

it comprises indexing pins for adjusting, during assembly, a positioning of the interconnector relative to the stator, the indexing pins being intended to cooperate with guide systems carried by insulators of reel

Methodology Applied

Scientific EffectMechanical alignment: Mechanical Fastener

Implementation Method 2

said interconnector being characterized in that it comprises indexing pins for adjusting, during assembly, a positioning of the interconnector relative to the stator

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentEP2677634B1Interconnector for a stator of an electric machine and stator comprising such an interconnector

Publication Date: 2022.11.30 VALEO EQUIP ELECTRIC MOTEUR

Figure 1~2b
Figure 2c~3a
Figure 3b~3c

AI summary

The interconnector (22) has a neutral frame (31) and three phase frames (32-34) of annular shape, where the frames are stacked axially on each other and insulated from each other. Each frame includes an internal lug (36) protruding inwardly of the frame for welding ends of coils of a stator. The neutral frame is intended to be connected to the neutral of a polyphase electrical machine, and the three phase frames are intended to be connected to the three phase of the electric machine, respectively.