Stator Guide Body Contours for DC Motor Winding Assembly
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Solution Overview
Problem
Existing electronically commutated DC motors face challenges in ensuring correct connection of in-phase winding ends to the power supply while maintaining efficient insulation and minimizing assembly effort, especially when dealing with large winding cross-sections and varying current requirements.
Innovation Solution
A stator design featuring a guide body with defined contours and recesses for connecting and insulating bodies, which ensures precise alignment and fixation of winding ends, preventing incorrect assembly and allowing for easy adaptation to different speeds and current intensities by implementing parallel and series circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If large cable cross-sections are used for winding ends to handle large currents, then current carrying capacity is improved, but installation space increases and insulation requirements become more stringent
Solution Approach 1:
The winding end connection system is segmented into multiple functional components: connecting bodies for electrical connection, insulating bodies for electrical isolation, and a guide body for positioning. This segmentation allows each component to be optimized independently, enabling large current carrying capacity while maintaining compact overall dimensions.
Solution Approach 2:
The guide body acts as an intermediary structure that receives the winding ends and guides them to the connecting bodies. This intermediary component enables precise positioning and alignment, ensuring reliable electrical connection while maintaining compact installation space and proper insulation.
2Reliability
If connector plates with welding are used to connect winding ends, then electrical connection is improved, but assembly complexity and risk of incorrect assembly increase
Solution Approach 1:
The connecting bodies feature asymmetric contours with specific engagement geometries that only fit in the correct orientation within the guide body. This asymmetric design provides foolproof assembly, ensuring that components can only be assembled correctly and eliminating the risk of incorrect wiring connections.
Solution Approach 2:
The guide body is pre-formed with specific recesses and contours that define the correct positions and orientations of the connecting bodies before assembly. This preliminary structuring of the guide body ensures that when components are assembled, they automatically achieve the correct configuration for reliable electrical connection.
3Reliability
If insulating bodies are placed between coils to ensure insulation, then electrical insulation is improved, but assembly effort and device complexity increase
Solution Approach 1:
The insulating bodies are merged into the overall connection assembly structure, where they are positioned between the connecting bodies and the stator core. This integration ensures that insulation is provided as an inherent part of the connection structure rather than as separate additional components, reducing overall assembly complexity.
Data Source
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Figure 3~4
AI summary
Stators for electronically commutated direct current motors are known that have a stator stack (10) having stator poles (12), between which grooves (14) are formed and on which coil windings (16) are arranged, winding ends (18) of the coil windings (16) being connected to an electronic circuit, via which the commutation signals can be supplied to the coil windings (16), and co-phasal coil windings (16) being connected to each other via connecting bodies (32, 36, 40) and non-co-phasal coil windings (16) being electrically isolated from each other by means of insulating bodies (34, 38). The installation and electrical connection of said stators can be adapted to different required loads only with great effort. To make this easier, the winding ends (18), according to the invention, project at a common axial end of the stator beyond the stator stack (10) into a guide body (22), which has a wall (24) that extends perpendicularly to the centre axis of the stator stack (10), on the axial face (30) of which wall opposite the stator stack (10) insulating bodies (34, 38) and connecting bodies (32, 36, 40) rest, wherein contours (44, 48) are formed on the connecting bodies (32, 36, 40), said contours engaging in corresponding contours (43, 46) that are formed on the guide body (22).