Electric Machine Stator Bridge Assembly
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Solution Overview
Problem
The assembly of electric machine stators, particularly the electrical bridges, is slow and costly due to the lack of automation in connecting conductive bar ends, which requires precise and labor-intensive manual operations.
Innovation Solution
The use of electrically insulating support and attachment plates with pre-assembled electrical bridges and interlocking mechanisms allows for automated mechanical and electrical connection of stator winding ends to the bridges, facilitating faster and more economical assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual assembly operations are used for electrical bridges, then precision and care can be maintained, but assembly speed and productivity are reduced
Solution Approach 1:
The patent replaces manual mechanical assembly operations with an automated mechanical system. The support plate with predefined seats and attachment mechanisms automatically positions and secures electrical bridges, eliminating the need for manual handling while maintaining precise positioning through the engineered seat geometries and attachment features.
Solution Approach 2:
The support plate structure incorporates self-aligning features where the seats automatically guide electrical bridges into correct positions during assembly. The attachment mechanisms are designed to self-lock into place, reducing the need for precise manual positioning while ensuring proper alignment and connection.
2Manufacturing precision
If manual assembly operations are used for electrical bridges, then complex precision operations can be performed, but labor costs and manufacturing costs increase
Solution Approach 1:
The patent divides the assembly system into modular components: support plates with predefined seats, electrical bridges with standardized connection points, and attachment mechanisms. This segmentation allows each component to be manufactured separately using optimized processes and then assembled automatically, reducing overall manufacturing complexity and cost.
Solution Approach 2:
The patent standardizes the geometrical parameters of seats and attachment mechanisms to work with standardized electrical bridges. By defining specific dimensional parameters and tolerances for the support plate features, the system achieves precise connections through repeatable manufacturing parameters rather than requiring skilled manual operations.
3Productivity
If automated assembly is implemented, then productivity and speed are improved, but device complexity increases
Solution Approach 1:
The support plate serves multiple functions simultaneously: it provides structural support for electrical bridges, defines precise positioning seats, incorporates attachment mechanisms for mechanical locking, and enables automated assembly. This multi-functionality reduces the need for separate components and simplifies the overall assembly system while maintaining high productivity.
Solution Approach 2:
The patent merges the support structure, positioning features, and attachment mechanisms into a single integrated support plate component. By combining these functions into one element, the system achieves automated assembly capability without requiring multiple separate devices or complex coordination between multiple components.
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 enables the automation of stator assembly, reducing manual intervention, time, and costs while ensuring precise electrical isolation and mechanical locking of electrical bridges, thereby improving the efficiency and cost-effectiveness of the process.
Implementation Method 1
The seat electrically insulates the electrical bridge from other components of the stator
Implementation Method 2
The seat is provided with attachment mechanisms which form at least partially a shaped coupling with the at least one electrical bridge, so as to mechanically lock it in position on the support and attachment plate
Data Source
AI summary
An electric machine comprising a stator including at least one stator winding elements that extends from a first to a second end, separate from each other; at least one electrical bridge suitable to electrically connect the separate ends of said stator winding element; at least a support and attachment plate made of electrically insulating material which defines at least one seat suitable to house at least partially, and retain in position, the electrical bridge. The seat is provided with attachment mechanisms which form at least partially a shaped coupling with the at least one electrical bridge, so as to mechanically lock it in position on the support and attachment plate. The seat allows the passage of the ends of the stator winding element and the electrical connection between the latter and the electrical bridge. The seat electrically insulates the electrical bridge from other components of the stator.