Stator Connection Overmolding for Compact Low-Vibration E-Machines
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Solution Overview
Problem
The production of rotary electrical machines is complicated by the need for precise placement and retention of complex electrical connection units during the welding process, leading to difficulties in size reduction and increased vibration.
Innovation Solution
The connection unit is partly over-moulded in an electrically insulating material, with electrically conductive elements extending radially to form connection outputs, facilitating easier installation and reducing size while minimizing vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex electrical connection unit is used to connect winding connection points, then reliable electrical connection is achieved, but the device size increases and manufacturing precision requirements increase
Solution Approach 1:
The electrically conductive elements are nested within the electrically insulating material, with the conductive elements forming connection outputs that extend radially from the insulating material. This nesting arrangement allows the connection unit to maintain reliable electrical connections while reducing overall size by efficiently utilizing internal space.
Solution Approach 2:
The connection unit comprises a composite structure combining electrically conductive elements with electrically insulating material. The insulating material over-moulded around the conductive elements provides both electrical insulation and structural support, enabling size reduction while maintaining connection reliability and reducing manufacturing complexity.
2Reliability
If a complex electrical connection unit is used to connect winding connection points, then reliable electrical connection is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The electrically insulating material is applied in advance to cover portions of the electrically conductive elements before final assembly. This preliminary action of over-moulding the insulating material simplifies the manufacturing process by eliminating the need for precise placement and retention of complex connection units during welding, as the insulating material is already in position.
Solution Approach 2:
The composite structure of insulating material surrounding conductive elements integrates multiple functions into a single component. The insulating material provides both electrical insulation and mechanical support, reducing the need for separate precision-aligned components and simplifying the manufacturing process.
3Adaptability or versatility
If a large-sized electrical connection unit is used, then all connection points can be connected, but vibrations during operation increase
Solution Approach 1:
The nested arrangement of conductive elements within the insulating material creates a compact, integrated connection unit that maintains full connection capability while reducing size. This compact structure minimizes vibration generation during operation compared to larger, more distributed connection units.
Data Source
AI summary
The invention relates to a rotary electric machine, in particular for a motor vehicle, including: a stator (100) comprising a stator body (110) and an electrical coil, said electrical coil including a plurality of phase windings (120) forming a bundle (125) that protrudes from an axial end face of the stator body, each phase winding including an end forming a coil connection point (122); and at least one electrical connection member (150) positioned in continuation of the stator (100) and comprising at least one electrically conductive element (155) which is overmolded with an electrically insulating material (126) and extends radially out of the electrically insulating material to form at least two connection outputs (153, 154) to which the connection points are connected.