Stator Cap Contact Hooks for Automated Round-Wire Phase Contacting
Solution Overview
Problem
Existing methods for connecting stator windings to phase contacts in electric motors, particularly in needle-wound or robot-wound stators, often result in incorrect contacts due to tolerance deviations and require complex, cost-intensive automation processes, especially when using conventional hook geometries with round wires.
Innovation Solution
A stator design featuring a hollow cylindrical base body with radially oriented teeth and a stator cap containing deformable contact hooks that automatically pre-position and center round wires during the winding process, ensuring secure contact without slippage and simplifying the automation of the caulking process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional hook geometries are used for contacting round wires of the stator winding, then the contacting process can be automated, but the automation process becomes complex and cost-intensive due to the need to maintain wire tension and prevent slippage
Solution Approach 1:
The stator cap is pre-equipped with integrated contact hooks that are positioned and configured before the winding insertion process. These hooks are designed to automatically capture and center the round wires during insertion, eliminating the need for complex tensioning mechanisms or post-positioning adjustments during automation.
Solution Approach 2:
The contact hooks on the stator cap are designed to self-center and self-capture the round wires during the insertion process. The hooks' geometry allows them to automatically grip the wires without requiring external positioning devices or complex control systems, making the automation process simpler and more cost-effective.
2Reliability
If insulation displacement contact technology is used to connect stator winding to phase contacts, then electrical contact is established, but tolerance deviations lead to undesirable faulty contacts
Solution Approach 1:
The contact hooks are pre-positioned on the stator cap and designed with specific geometries that automatically center the round wires during insertion. This preliminary positioning ensures that the wires are correctly aligned before the insulation displacement contact process begins, compensating for tolerance deviations in the winding process.
Solution Approach 2:
The contact hooks are designed with optimized geometric parameters including opening angles and dimensions that allow them to accommodate tolerance variations in wire positioning. The hooks can adapt their gripping position within certain ranges while maintaining reliable electrical contact, effectively compensating for manufacturing tolerances.
3Strength
If a hot-staking process is used with conventional hook geometries, then secure contact is achieved, but the wire loop must be under tension during insertion to prevent slippage
Solution Approach 1:
The contact hooks on the stator cap are designed to automatically capture and hold the wire loops during insertion without requiring external tensioning devices or complex positioning mechanisms. The hooks' geometry enables them to self-adjust and maintain the wire in position throughout the hot-staking process.
Solution Approach 2:
The hooks are pre-configured on the stator cap to receive and position the wire loops before the hot-staking process begins. This preliminary positioning ensures that the wires are correctly placed and held in position during insertion, eliminating the need for complex tensioning arrangements.
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 design enables fail-safe, tolerance-independent, and easily automated contacting of stator windings with phase contacts, reducing the complexity and cost of the automation process while ensuring reliable electrical connections.
Implementation Method 1
at least one contact terminal with a deformable contact hook, which receives the at least one winding section (round/wire, coil end) during a joining process and, following a deformation process, makes permanent contact
Data Source
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AI summary
The invention relates to a stator (1) of an electric motor, comprising a stator base body (2) with radially oriented stator teeth (5) which carry coils (6) of a multiphase coil winding (3), and a stator cap (10) with at least one receiving contour (13) into which at least one winding section (12) of the stator winding (3) is inserted, and with at least one contact connection (15) with a deformable contact hook (14) which receives the winding section (12) in the course of a joining process and subsequently makes captive contact following a deformation process.