Stator Contact Conductors with Hooks for Winding Connections
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Solution Overview
Problem
The complex and costly process of connecting stator windings in electrical machines, particularly in the automotive sector, is challenging due to the need for individual contacts and complicated wire laying, which increases production time and risk of errors.
Innovation Solution
A stator arrangement using continuous sheet metal contact conductors with hooks and terminal lugs for simplified electrical connections between stator windings, reducing the need for individual wire connections and minimizing the complexity of wire laying by using hooks to securely clamp winding wire ends.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual contacts are used to connect stator windings, then electrical connection is achieved, but the complexity of wire laying and production time increase significantly
Solution Approach 1:
Multiple individual contacts are merged into a single continuous contact conductor that spans across multiple stator windings. This continuous conductor integrates the function of multiple separate contacts, eliminating the need for complex individual wire laying while maintaining reliable electrical connections to all necessary windings simultaneously.
Solution Approach 2:
The continuous contact conductor serves multiple functions: it provides electrical connection to multiple stator windings, acts as a structural support element, and eliminates the need for separate individual contacts. This multi-functional design simplifies the overall connecting device structure while maintaining connection reliability.
2Reliability
If individual contacts are fixed in insulating end plate before winding, then electrical connection is established, but production time and manufacturing complexity increase
Solution Approach 1:
The continuous contact conductor is pre-formed with appropriate geometry and connection points before the winding process. This preliminary preparation allows the conductor to be directly installed and connected during winding without requiring time-consuming individual contact fixation steps, thereby reducing production time while ensuring reliable electrical connections.
3Reliability
If multiple stator windings are connected via wire routing between stator teeth, then electrical connection is achieved, but the routing becomes complicated and time-consuming
Solution Approach 1:
Multiple separate wire routing paths between stator teeth are merged into a single continuous contact conductor that provides all necessary connections in one element. This eliminates the need for complex multi-path wire routing and simplifies the manufacturing process while maintaining reliable electrical connections between all stator windings.
Data Source
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AI summary
The present invention relates to a stator arrangement for an electric machine, comprising a stator laminate stack, comprising a multiplicity of stator windings, comprising a contact-making device which has at least one contact conductor, which is designed to electrically connect at least two stator windings to one another, wherein a respective contact conductor has at least one connecting lug for electrically coupling an external connection unit to the contact-making device and at least one hook for receiving a winding wire end of a stator winding connected electrically in each case to the contact conductor. The present invention relates to an electric machine comprising such a stator arrangement.