Universal Stator Interconnection Housing for Delta-Star Assembly

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Solution Overview

Problem

Existing stator units for electric machines require complex and costly assembly processes to switch between delta and star connections, with inefficient use of insulation housings and interconnection devices.

Innovation Solution

Designing stator units with identical receiving structures and insulation housings for both delta and star connections, allowing for the same interconnection devices to be used by adding or omitting a star point rail, and optimizing connection lug arrangements to simplify assembly and reduce manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If different interconnection devices are used for delta and star connections, then the connections can be formed, but the device complexity and manufacturing cost increase

Engineering Contradiction:

Improveconnection typeVSAvoidinterconnection device

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The receiving structure is designed to accommodate both delta and star connections through a universal design. The same receiving structure can hold different interconnection devices (delta interconnection device or star interconnection device) depending on the required connection type, eliminating the need for separate receiving structures for each connection type.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The interconnection system is divided into separate functional components: the receiving structure (which is universal) and the interconnection devices (which are specific to delta or star connections). This segmentation allows the universal receiving structure to be combined with different interconnection devices to achieve different connection types without increasing overall system complexity.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If different receiving structures are used for delta and star connections, then the connections can be formed, but the manufacturing cost and assembly complexity increase

Engineering Contradiction:

Improveconnection typeVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

A single universal receiving structure design is used for both delta and star connections. This receiving structure can be manufactured once and used for both connection types, reducing manufacturing costs associated with producing multiple different receiving structures.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The receiving structure for delta connection and the receiving structure for star connection are merged into a single universal design. This consolidation reduces the total number of unique parts that need to be manufactured, thereby lowering manufacturing costs.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If different insulation housings are used for delta and star connections, then the connections can be formed, but the manufacturing cost increases

Engineering Contradiction:

Improveconnection typeVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The insulation housing is designed as a universal component that can accommodate both delta and star interconnection devices. This single insulation housing design replaces the need for separate insulation housings for each connection type, reducing manufacturing costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Adaptability or versatility

If complex assembly processes are used to switch between delta and star connections, then the connections can be formed, but the assembly time and cost increase

Engineering Contradiction:

Improveconnection typeVSAvoidassembly time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The system is segmented into a universal receiving structure and interchangeable interconnection devices. To switch between delta and star connections, one simply replaces the interconnection device while the receiving structure remains in place, significantly reducing assembly time compared to redesigning the entire connection system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The receiving structure is pre-designed with universal features that accommodate both delta and star connections. This preliminary design decision enables quick switching between connection types without requiring complex assembly procedures or extensive modifications during the assembly process.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250364859A1Set with two stator units, stator unit for a set, and method for manufacturing the stator units

Publication Date: 2025.11.27 ZF FRIEDRICHSHAFEN AG

AI summary

A set having a first stator unit, with a first interconnection device for interconnecting a stator winding to form a delta circuit, the first interconnection device having three connection rails for contacting respective phase strands of the stator winding and an insulation housing with a receiving structure for receiving the connection rails; and a second stator unit having a second interconnection device for interconnecting a stator winding to form a star point circuit, the second interconnection device having three connection rails, each for contacting one phase strand of the stator winding, a star point rail for contacting all phase strands of the stator winding and an insulation housing with a receiving structure for the connection and the star point rails.; The receiving structures of the first and second interconnection devices are of identical construction and/or the insulation housings of the first and second interconnection devices are identical parts.