Stator Connection Assembly With Radial Winding-Head Positioning
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Solution Overview
Problem
The irregular shape of winding heads due to manufacturing tolerances complicates the accurate positioning of connection devices on stators, hindering automated manufacturing processes.
Innovation Solution
A stator device with a connection device featuring a plate-shaped isolating body and protruding holding elements that radially attach to the winding head, along with elastically deformable and counterforce-absorbing elements to secure the connection device, allowing for precise positioning and robustness against manufacturing tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the connection device is directly arranged axially on the winding head, then the structure is simple, but the positioning accuracy deteriorates due to irregular shape of winding head from manufacturing tolerances
Solution Approach 1:
The holding elements extend in the radial direction (perpendicular to the axial arrangement direction) to engage with the winding head, adding a radial dimension to the positioning mechanism. This radial engagement provides precise positioning while maintaining simple axial arrangement of the main body, resolving the contradiction between structural simplicity and positioning accuracy.
2Manufacturing precision
If holding elements are added to the isolating body, then positioning accuracy improves, but device complexity increases
Solution Approach 1:
The connection device is segmented into the isolating body and separate holding elements. The holding elements are designed as distinct components that can be integrated into the isolating body, allowing the main structure to remain simple while adding positioning functionality through these separate elements.
Solution Approach 2:
The holding elements act as intermediary components between the isolating body and the winding head. They provide the positioning function by engaging with the winding head's geometry, allowing the isolating body to maintain its simple axial arrangement while achieving precise positioning through these intermediary elements.
3Reliability
If the connection device is designed for radial holding on the winding head, then robustness against manufacturing tolerances improves, but the ease of manufacture deteriorates
Solution Approach 1:
The holding elements are designed to automatically engage with the winding head's geometry through radial projection. The elastically deformable nature of the holding elements allows them to self-adjust and snap into position during assembly, eliminating the need for complex alignment procedures or additional fastening operations in automated manufacturing processes.
Solution Approach 2:
The holding elements are made elastically deformable, changing their mechanical parameter from rigid to flexible. This allows them to deform during assembly to accommodate slight variations in winding head geometry, then maintain a stable holding force once positioned, providing robustness against manufacturing tolerances while simplifying the assembly process.
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
Facilitates automated manufacturing by preventing radial and axial slipping, enhancing the connection device's robustness and simplifying the assembly process.
Implementation Method 1
the holding elements comprise holding elements of a first type which are elastically deformable at least in sections such that they exert a restoring force for holding the isolating body on the winding head
Implementation Method 2
the holding elements comprise holding elements of a second type which are designed to absorb a counterforce of the restoring force
Data Source
AI summary
A stator device for an electric machine includes a stator, having a stator core with a longitudinal axis, a first end face and a second end face which is situated axially opposite the first end face with respect to the longitudinal axis, and having a stator winding which forms a winding head on the first end face and has a plurality of connection portions extending beyond the winding head. The isolating body has a plurality of holding elements, which protrude from the base portion on the second side and are designed to hold the isolating body radially on the winding head.