Stator Busbar Sensor Mounting for Replaceable Temperature Detection

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Solution Overview

Problem

Existing interconnection arrangements for stator coils in electrical machines face challenges in temperature detection and sensor replacement, often resulting in damage to electrical contacting points or increased risk of stator damage.

Innovation Solution

The proposed interconnection arrangement includes a receiving element outside the interconnection region, thermally coupled to the connector ring segment or busbar, allowing for secure mounting and easy replacement of temperature sensors without risking damage to current paths.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the temperature sensor is secured directly on a coil conductor or connecting conductor in the interconnection region, then the temperature can be detected, but the replaceability of the sensor is compromised and damage to electrical contacting points may occur

Engineering Contradiction:

Improvetemperature detectionVSAvoidsensor replacement

Core Design Contradiction:

Measurement precisionVSEase of repair

Solution Approach 1:

The connector ring is divided into two distinct regions: an interconnection region for electrical contacts and a sensor region for temperature sensing. This segmentation allows the temperature sensor to be mounted on the connector ring without interfering with electrical contacting points, enabling both accurate temperature detection and easy sensor replacement.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The temperature sensor is extracted from the interconnection region and placed in a dedicated sensor region on the connector ring. This extraction eliminates the conflict between sensor mounting and electrical contacting, allowing the sensor to be replaced without risking damage to electrical contacts while maintaining temperature detection capability.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If the temperature sensor is secured by injection-molded encapsulation or soldered joints, then the sensor is firmly fixed, but demounting the sensor increases the risk of damage to stator parts or causes short circuits

Engineering Contradiction:

Improvesensor fixing durabilityVSAvoidsensor demounting safety

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The connector ring is segmented into an interconnection region and a sensor region, allowing the temperature sensor to be mounted in a location that does not interfere with electrical contacts. This enables the sensor to be firmly fixed for reliable temperature detection while allowing safe demounting without risking damage to stator parts or causing short circuits.

Inventive Principle:

Principle #1Segmentation

3Measurement precision

If the temperature sensor is positioned in the interconnection region, then temperature detection is achieved, but the complexity of the interconnection arrangement increases and sensor replacement becomes difficult

Engineering Contradiction:

Improvetemperature measurementVSAvoidinterconnection arrangement complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The connector ring is divided into an interconnection region for electrical contacts and a sensor region for temperature sensing. This segmentation simplifies the overall arrangement by clearly separating functional zones, reducing complexity while enabling accurate temperature measurement without interfering with electrical connections.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connector ring serves multiple functions: it provides electrical interconnection through the interconnection region and temperature sensing through the sensor region. This multi-functionality is achieved through a single integrated component design, reducing the need for additional separate components and simplifying the overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 design enables accurate temperature measurement of the stator and interconnection arrangement while simplifying the replacement of temperature sensors, minimizing the risk of damage to electrical contacts and stator components.

Implementation Method 1

the receiving element is coupled at least thermally to the connector ring segment or the busbar within the interconnection region

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12212204B2Wiring configuration for a stator, temperature sensor device, and system for detecting a temperature

Publication Date: 2025.01.28 ZF FRIEDRICHSHAFEN AG

AI summary

The disclosure relates to a wiring configuration for a stator of an electric machine. The wiring configuration comprises a busbar which forms a segment of a switching ring with an outer connection and a winding connection. Outer connection elements and winding connection elements are arranged in a wiring region. The wiring configuration additionally comprises a receiving element which is at least thermally coupled to the busbar. The receiving element is arranged outside of the wiring region. The disclosure additionally relates to a temperature sensor device for plugging onto the receiving element of the wiring configuration and to a system for detecting the temperature of a stator.