Star Point Connection Using Nested Crimp Sleeves
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Solution Overview
Problem
Existing star point connections in electric motors require significant space and are complex to implement and maintain, especially in three-phase motors, due to the need for large recesses in the stator housing and multiple connections.
Innovation Solution
The method involves using crimp sleeves to create a star point connection within the stator winding area by connecting individual stator winding wires with crimped and welded crimp sleeves, allowing for a compact, reliable, and easily controllable connection, with stranded wires providing redundancy and high current capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional star point connections are implemented in electric motors, then the stator windings can be connected in a star configuration, but significant space is required and the implementation becomes complex
Solution Approach 1:
The patent implements nesting by placing crimp sleeves inside the stator winding bore, with first crimp sleeves on individual winding wires and second crimp sleeves on a common electrical line (stranded wire). The second crimp sleeves are nested within the stator winding bore, creating a compact hierarchical structure that eliminates the need for large external connection areas while maintaining reliable electrical connections.
Solution Approach 2:
The patent introduces crimp sleeves as intermediary components between the stator winding wires and the electrical lines. These crimp sleeves serve as mediators that facilitate reliable electrical connections through crimping and welding, simplifying the connection process and improving reliability without requiring complex direct wiring arrangements.
2Reliability
If traditional star point connections are implemented in electric motors, then the stator windings can be connected in a star configuration, but large recesses in the stator housing are required
Solution Approach 1:
The patent places the entire connection system within the existing stator winding bore, nesting the crimp sleeves and electrical lines inside the motor housing without requiring additional external space. This nested arrangement eliminates the need for large recesses in the stator housing while maintaining reliable star point connections.
Solution Approach 2:
The patent transitions from a two-dimensional surface connection approach to a three-dimensional volumetric arrangement within the stator winding bore. By utilizing the internal volume of the stator winding bore and arranging components in multiple dimensions, the connection system achieves reliable connections without increasing the external footprint or requiring large housing recesses.
3Volume of stationary object
If multiple connections are made at a single common point, then the star point connection is compact, but the connection points are difficult to access and control
Solution Approach 1:
The patent segments the connection system by providing separate second crimp sleeves for each phase connection point along the stranded wire, rather than making all connections at a single common point. This segmentation allows each connection point to be individually accessed and controlled while maintaining a compact overall structure within the stator winding bore. The spaced-apart arrangement of second crimp sleeves enables individual access to each connection point.
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 approach minimizes space requirements, simplifies the connection process, ensures high reliability, and allows for easy access and monitoring of the star point, while enabling high current transmission with low contact resistance.
Implementation Method 1
the first crimp sleeves (5) being connected to second crimp sleeves (6) by means of a respective welded connection (40)
Implementation Method 2
the crimp sleeves are crimped on
Data Source
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AI summary
An arrangement for producing a star connection in the case of an electromotor, in particular three-phase motor; first crimp sleeves being slid onto stator winding-wire end regions and joined thereto; the first crimp sleeves being joined to the second crimp sleeves by a respective welded connection; the second crimp sleeves being slid onto an electrical line and joined thereto.