Stator Insulating Cap Layout for Stable Coil Wire Contact
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Solution Overview
Problem
Existing brushless electric motors face issues with coil wire damage due to tensile stress, off-center positioning, and slippage during insulation displacement contact, which can lead to poor electrical contact and increased risk of short circuits.
Innovation Solution
A stator design featuring a stator core with stamped laminated core, insulating cap, and contact receiving pockets with deflection balconies and elastic subregions, along with wire guide contours, ensures precise and damage-free coil wire guidance and contact, reducing tensile stress and preventing slippage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation displacement contacts are set to contact the coil wire, then electrical contact is achieved, but tensile stress damages the coil wire
Solution Approach 1:
The patent applies beforehand cushioning by creating a slack in the coil wire before the insulation displacement contact is set. This slack acts as a buffer that absorbs the tensile stress generated during contact setting, preventing damage to the coil wire while still achieving reliable electrical contact. The cushioning is prepared in advance during the wire insertion process.
2Reliability
If insulation displacement contacts are pressed in to ensure contact, then electrical connection is improved, but coil wire may lie off-center and not be correctly contacted
Solution Approach 1:
The patent applies self-service through the elastic receiving pocket that automatically adjusts to center the coil wire. The elastic material deforms to accommodate the wire and then restores its shape to apply gentle centering forces, ensuring the wire is correctly positioned without requiring additional manual adjustment or complex positioning mechanisms.
3Reliability
If insulation displacement contact is used for coil wire contact, then electrical connection is achieved, but coil wire can slip out under temperature changes
Solution Approach 1:
The patent applies parameter changes by utilizing the elastic properties of the receiving pocket material. The elastic material's ability to deform and restore allows it to maintain contact pressure on the coil wire across varying temperature conditions, preventing slippage while accommodating thermal expansion and contraction of the 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
The solution provides reliable and continuous electrical contact, minimizing coil wire damage and short circuits, while ensuring proper alignment and reducing the risk of slippage under temperature changes.
Implementation Method 1
The receiving region (12) has an upper (14) and a lower elastic subregion (15)... The lower subregion (15) is made of an elastic material or is designed to be elastically flexible
Implementation Method 2
a number of deflection balconies (13a, 13b, 13c, 13d)... wire guide contours (10) on the outer peripheral surface (11) of the insulating cap (7) for spacing the coil wire (5)
Implementation Method 3
at least one insulating cap (7) on which a plurality of contact receiving pockets (8, 8a, 8b, 8c, 8d) is arranged for receiving the coil wire (5)
Data Source
AI summary
A stator for an electric drive unit, in particular an electric motor, and to a method for the production thereof. The stator for the electric drive unit comprises a stator core having at least one stator pole; a stator winding which forms all coils from a continuous winding wire; at least one insulating cap, on which a plurality of contact receiving pockets are arranged for receiving the winding wire; a number of deflection domes which are distributed on the outer lateral surface of the cap; and wire guiding contours at the outer lateral surface of the insulting cap for spacing the winding wire; wherein the plurality of contact receiving pockets each have a receiving region for the winding wire which has a different design, and wherein the plurality of contact receiving pockets comprise at least one deflection balcony.