Stator Assembly Ground Pin Integration Before Plastic Overmolding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge of achieving effective electrical grounding of stator laminations in electric motor stator assemblies is complicated by the overmolding process, which hinders direct electrical contacting.
Innovation Solution
A method for producing a stator assembly that involves mounting a ground contact pin on the laminated core with a coil former, followed by overmolding, thereby establishing a ground connection without subsequent processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the stator lamination is completely overmolded with plastic, then the electromagnetic compatibility is improved through insulation, but the electrical contacting for ground connection becomes more difficult
Solution Approach 1:
The ground contact pin is mounted on the laminated core before the overmolding process. This preliminary action ensures that the electrical contact path is established before the plastic encapsulation, allowing the ground connection to be made through the pin that protrudes from or is embedded in the overmolded stator, thus maintaining ease of electrical contacting while achieving complete insulation coverage
2Reliability
If a ground connection is made by subsequent processing of the overmolded stator, then the electromagnetic compatibility is improved, but additional processing steps are required
Solution Approach 1:
The ground contact pin is installed on the laminated core before overmolding, eliminating the need for subsequent processing steps to create ground connections. This preliminary installation of the contact pin allows the ground connection to be established as part of the assembly process rather than as a separate post-processing operation, thereby improving productivity
Solution Approach 2:
The mounting of the ground contact pin is combined with the coil former mounting process. The pin is attached to the laminated core while the coil formers are being installed, merging two operations into one coordinated process step, which reduces the total number of processing steps and improves production efficiency
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 allows for a reliable and efficient ground connection to be established during the production of stator assemblies, enhancing electromagnetic compatibility without requiring additional processing steps.
Implementation Method 1
the ground contact pin is mounted as a press-fit pin. Specifically, a press-fit connection is in this case established with the receptacle provided on the coil former, with this press-fit connection creating the necessary contact with the laminated core of the stator assembly
Data Source
AI summary
A method for producing a stator assembly of an electric motor includes: providing a laminated core of the stator assembly; mounting at least one coil former on the laminated core; mounting a ground contact pin on the laminated core provided with the coil former; and overmolding the laminated core with plastic.