Stator Bus Bar Ring With Integral Staking for Secure Assembly
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Solution Overview
Problem
Securing bus bars in the support ring of a stator is difficult due to limited installation space, and existing methods are costly and inefficient.
Innovation Solution
Integrate bus bars into a plastic support ring with concentric annular grooves using a bus bar securing element formed by plastic deformation of a staking element, which captively holds the bus bars in the grooves without additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bus bars are overmolded in the support ring or placed in a shell-like receptacle, then the bus bars are secured in the support ring, but additional components and installation space are required
Solution Approach 1:
The bus bar securing element is integrally formed with the support ring as a single plastic component, merging two previously separate elements (support ring and securing mechanism) into one unified structure. This eliminates the need for additional securing components while maintaining reliable bus bar fixation.
Solution Approach 2:
The support ring serves multiple functions: it provides structural support for the bus bars, guides their positioning through annular grooves, and secures them through the integrally formed bus bar securing elements. This multi-functionality eliminates the need for separate securing components.
2Reliability
If bus bars are overmolded in the support ring or placed in a shell-like receptacle, then the bus bars are secured in the support ring, but additional installation space is required
Solution Approach 1:
The securing function is merged into the support ring structure itself through integral formation of the bus bar securing element. This eliminates the need for additional space-consuming separate securing components while maintaining reliable bus bar fixation within the same installation envelope.
Solution Approach 2:
The bus bar securing element is nested within the support ring structure, with the securing element forming an integral part of the support ring's body. This nested integration allows the securing mechanism to occupy no additional installation space beyond what is already required for the support ring itself.
3Reliability
If conventional securing methods are used, then bus bars can be secured, but the manufacturing process becomes expensive and complex
Solution Approach 1:
The support ring and bus bar securing element are manufactured as a single integral plastic component, combining two manufacturing steps into one. This reduces manufacturing complexity and cost while ensuring reliable bus bar securing through the integrated design.
Solution Approach 2:
The invention changes the manufacturing approach from assembling separate metal and plastic components to molding a single plastic component with integrated securing elements. This parameter change in manufacturing methodology reduces both cost and complexity while maintaining securing reliability.
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
Provides a secure and cost-effective integration of bus bars without additional installation space, enhancing manufacturing efficiency and reliability.
Implementation Method 1
the bus bar securing element was shaped by plastic deformation of a staking element, which is formed integrally with the support ring, in the axial direction from the support ring between two adjacent annular grooves
Data Source
AI summary
A stator for an electric machine, having a winding including a plurality of interconnected conductors which are assigned to one or more phases, wherein: ends of at least some of the conductors project axially or radially beyond the winding. An interconnection ring having at least one support ring on which at least one bus bar is arranged is axially placed onto the winding, and the support ring is formed from a plastic and has concentrically extending annular grooves in each of which at least one bus bar is arranged. At least one end of a conductor is connected to a bus bar, at least one bus bar arranged in an annular groove is captively held in the annular groove by means of a bus bar securing element which overlaps at least portions of the annular groove in the radial direction, and the bus bar securing element as shaped by plastic deformation of a staking element which is formed integrally, in the axial direction from the support ring between two adjacent annular grooves, with the support ring.