Stator Decoupling Element Assembly for Vibration Isolation
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Solution Overview
Problem
The complex design and mounting process of decoupling elements in electric machines, which require precise alignment and vulcanization of multiple components, makes the process difficult and prone to errors, especially when dealing with stators composed of multiple thin electrical sheets.
Innovation Solution
A simplified 2-part decoupling element with an elastic sheath having a larger outside diameter than the through-hole is pressed into the hole through a funnel-like insertion opening, allowing radial compression and secure clamping without the need for flanging, using a lubricating fluid to reduce friction during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a 3-part decoupling element with precise outer sleeve and inner sleeve alignment is used, then vibration decoupling performance is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines the outer sleeve and inner sleeve into a single integrated decoupling element with a pre-formed funnel-like insertion opening. This merging eliminates the need for separate alignment and positioning of multiple components, reducing assembly complexity while maintaining the vibration decoupling function through the elastic damping material.
Solution Approach 2:
The decoupling element is segmented into distinct functional zones: a funnel-like insertion opening for simplified mounting, an elastic damping material zone for vibration decoupling, and an axial locking zone. This segmentation allows each part to perform its specific function optimally without requiring complex interactions between multiple components.
2Reliability
If multiple components are assembled with precise alignment, then mounting reliability is improved, but ease of manufacture deteriorates
Solution Approach 1:
The funnel-like insertion opening is pre-formed as an integral part of the decoupling element during manufacturing. This preliminary action eliminates the need for complex alignment operations during assembly, as the funnel shape naturally guides the decoupling element into the correct position within the through-hole, ensuring reliable mounting without requiring precise manual or machine alignment.
Solution Approach 2:
The funnel-like insertion opening acts as an intermediary feature that mediates between the decoupling element and the through-hole. It provides a transition zone that facilitates easy insertion while ensuring proper positioning, thereby simplifying the assembly process without compromising mounting reliability.
3Ease of operation
If the outside diameter of the sheath matches the inside diameter of the through-hole precisely, then ease of operation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The decoupling element features an asymmetric diameter profile: a larger outside diameter at the insertion opening (forming the funnel shape) and a reduced outside diameter in the main body portion. This asymmetry allows the insertion to be easily performed through the larger opening while the reduced diameter portion provides the necessary clearance and fit within the through-hole, eliminating the need for precise diameter matching throughout the entire component.
Solution Approach 2:
The solution transitions from a 2-dimensional diameter matching problem to a 3-dimensional geometric solution. By creating a funnel-like shape with varying diameter along the axial dimension, the patent enables easy insertion through the larger opening while maintaining proper fit in the through-hole, thereby reducing manufacturing precision requirements without compromising ease of operation.
4Reliability
If flanging is performed to reduce play to zero, then axial locking reliability is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent extracts the axial locking function from the flanging operation and integrates it directly into the decoupling element design. The element is configured to engage with the bottom of the through-hole and provide axial positioning through its geometric shape and elastic damping material, eliminating the need for separate flanging operations to achieve axial locking.
Solution Approach 2:
The decoupling element is designed to be self-locking axially through its own geometric features and elastic properties. The element automatically positions itself axially within the through-hole during insertion, providing self-service axial locking without requiring additional flanging operations or external locking mechanisms, thereby simplifying the mounting process while maintaining reliability.
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 method simplifies the mounting process by eliminating the need for complex alignment and vulcanization, ensuring a firm clamping coupling and secure axial fixation while reducing the risk of damage to the elastic material, thus facilitating easier assembly and improved vibration decoupling.
Implementation Method 1
an elastic sheath which is fastened to the sleeve, surrounds the sleeve, and which is made of a damping material, via which the stator in the mounted position is vibrationally decoupled from a housing of the electric machine
Implementation Method 2
The outside diameter of the sheath is larger than the inside diameter of the through-hole... When the decoupling element is inserted into the through-hole and the elastic damping material rests against the inside wall of the through-hole, this inevitably has the result that the damping material is compressed radially
Implementation Method 3
using a lubricating fluid to reduce friction during installation
Data Source
AI summary
The disclosure relates to a method for mounting a decoupling element in a through-hole in a stator of an electric machine. The decoupling element comprises a sleeve and an elastic sheath, which is fastened to the sleeve and surrounds the sleeve and is made of a damping material. In the mounted position, the stator is vibrationally decoupled from a housing of the electric machine by means of said damping material. The decoupling element, the elastic sheath of which has an outside diameter greater than the inside diameter of the through-hole, is pressed into the through-hole through an insertion opening, which expands in the manner of a funnel. In the mounted position, the decoupling element is seated directly against the inside wall of the through-hole.