End-Side Stator Interconnection Module for Compact Motor Layout
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Solution Overview
Problem
Conventional stator arrangements for electric motors have large axial dimensions and high material consumption due to the need for wire guidance through annular regions, which also results in poor thermal response for heat dissipation.
Innovation Solution
A stator arrangement with a separate interconnection module positioned on the end side of the stator, featuring integral electrical terminal conductors embedded in an insulating material, which decouples the interconnection from the stator winding and eliminates the need for wire guidance between poles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wire guidance through annular regions is used in conventional stator arrangements, then electrical interconnection between poles is achieved, but axial dimensions and material consumption increase
Solution Approach 1:
The patent relocates the interconnection function from the radial/annular region to the axial end side of the stator. By positioning terminal conductors and connection elements on the end plates rather than routing wires through the annular region between poles, the design achieves electrical interconnection without increasing axial dimensions significantly, as the interconnection now occurs in the axial plane rather than requiring radial space.
Solution Approach 2:
The patent separates the stator winding from the interconnection system by introducing distinct terminal conductors and connection elements. The winding remains on the stator core while interconnection is handled by separate terminal conductors embedded in the end plate, allowing independent optimization of each function and eliminating the need for complex wire guidance through annular regions.
2Ease of operation
If wire guidance through annular regions is used in conventional stator arrangements, then electrical interconnection between poles is achieved, but material consumption increases
Solution Approach 1:
The patent merges the terminal conductor with the end plate structure by embedding the terminal conductors directly into the end plate material. This integration eliminates the need for separate wire guidance structures, annular regions, and additional insulation components, thereby reducing overall material consumption while maintaining electrical interconnection functionality.
Solution Approach 2:
The patent extracts the interconnection function from the stator core and annular region, relocating it to the end plate. This separation allows the use of more efficient materials and structures for interconnection at the end plate, reducing material consumption compared to the conventional approach of routing wires through the annular region.
3Ease of operation
If conventional stator winding interconnection is used, then electrical connectivity is achieved, but thermal response for heat dissipation is poor
Solution Approach 1:
The patent introduces the end plate as an intermediary thermal management component. By embedding terminal conductors in the end plate and using the end plate structure itself for interconnection, the design creates additional thermal pathways through the end plate material, improving heat dissipation from the winding to the stator core and surrounding cooling structures.
Data Source
AI summary
A stator arrangement for an electric machine includes a stator comprising a stator core on which a stator winding has been arranged. The arrangement also includes an interconnection module for electrically interconnecting winding wire ends of the stator winding. The interconnection module is positioned on the stator on the end side. The interconnection module comprises integral electrical terminal conductors which are embedded at least partially in a body including an electrically insulating material. The terminal conductors each form a terminal contact to which an external power supply and/or control of the stator arrangement can be connected and a winding contact which is electrically conductively connected to a winding wire end.