Stator Busbar Receiving Structure for Replaceable Temperature Sensing
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Solution Overview
Problem
Existing stator designs for electrical machines face challenges in temperature detection and sensor replacement, as attaching temperature sensors can lead to damage of electrical contact points and increased risk of short circuits due to the need for overmolding or solder connections.
Innovation Solution
A stator design with a temperature sensor receiving area that is thermally coupled to the interconnection arrangement, allowing for easy installation and replacement of sensors without damaging contact points, using a busbar with a protruding extension for the sensor to be plugged or pushed onto, and utilizing a sensor housing for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the temperature sensor is mounted directly on the coil conductor or connecting conductor of the wiring arrangement, then the temperature can be detected accurately, but the replaceability of the sensor leads to damage to the electrical contact point
Solution Approach 1:
The patent divides the temperature sensing function from the electrical contact function by providing a dedicated temperature sensor receiving area on the busbar that is separate from the wiring area where electrical contacts are made. This segmentation allows the temperature sensor to be mounted without interfering with electrical contact points, thus maintaining both measurement accuracy and contact integrity.
Solution Approach 2:
The busbar serves as an intermediary structure that simultaneously provides both electrical connection functionality and temperature sensing functionality. The temperature sensor receiving area on the busbar acts as a mediator that transfers thermal information from the wiring arrangement to the temperature sensor without requiring direct contact between the sensor and electrical contact points.
2Stability of the object's composition
If the temperature sensor is secured with overmold or soldered connections, then the sensor fixation is permanent and secure, but disassembly increases the risk of damage to stator components or causes short circuits
Solution Approach 1:
The patent segments the sensor mounting function from the electrical functionality by providing a dedicated temperature sensor receiving area on the busbar. This receiving area is designed with specific geometric features (such as recesses or protrusions) that enable secure mechanical fixation of the temperature sensor through press-fit or snap-fit connections, allowing easy removal and reinstallation without damaging electrical components.
Solution Approach 2:
The temperature sensor receiving area is designed as a simple, replaceable structure on the busbar that can accommodate the temperature sensor without requiring permanent attachment methods. The sensor can be easily replaced if needed, and the receiving area itself serves as a disposable or replaceable component that protects the main stator structure from damage during sensor replacement operations.
3Device complexity
If the temperature sensor receiving area is integrated into the wiring area, then the structure is compact, but the sensor installation and replacement becomes complex and risky
Solution Approach 1:
The patent divides the busbar structure into distinct functional areas: a wiring area for electrical connections and a temperature sensor receiving area for sensor mounting. This segmentation allows each area to be optimized for its specific function - the wiring area maintains electrical integrity while the sensor receiving area provides easy access and simple installation procedures for temperature sensors.
Solution Approach 2:
The busbar is designed with different local qualities in different areas: the wiring area has properties optimized for electrical conduction and connection, while the temperature sensor receiving area has geometric features (such as recesses, protrusions, or specific surface characteristics) optimized for sensor mounting and easy replacement. This local differentiation enables both compact integration and ease of operation.
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
Enables accurate temperature measurement of the stator while minimizing the risk of damage to electrical contacts during sensor replacement, with improved thermal conductivity and ease of installation, allowing for simple and cost-effective temperature detection.
Implementation Method 1
a temperature sensor receiving area (12) for attaching a temperature sensor, the temperature sensor receiving area being formed outside a wiring area (22) of the wiring arrangement (10) and being thermally coupled to the interconnection arrangement (10)
Data Source
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AI summary
The invention relates to a wiring configuration (10) for a stator (100) of an electric machine. The wiring configuration (10) comprises a busbar (14) which forms a segment of a switching ring with an outer connection (16) and a winding connection (18). Outer connection elements and winding connection elements are arranged in a wiring region (22). The wiring configuration (10) additionally comprises a receiving element (12) which is at least thermally coupled to the busbar (14). The receiving element (12) is arranged outside of the wiring region (22). The invention additionally relates to a temperature sensor device (50) for plugging onto the receiving element (12) of the wiring configuration (10) and to a system (74) for detecting the temperature of a stator (100).