Stator Insulating Lamella Form-Fitting Connection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing stator assembly processes for electrical machines are complex and prone to misalignment of components during assembly, leading to potential separation of individual parts during winding, which complicates the application of stator windings.
Innovation Solution
A stator design featuring a form-fitting connection between insulating and cover laminas using fixing bolts and recesses, ensuring a positive connection in all orthogonal directions, with the fixing bolt optionally being part of the insulating lamella and clamping ribs for enhanced friction, allowing for easy assembly and reduced risk of separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional assembly methods without form-fitting connections are used, then the assembly process is simpler in terms of connection design, but the individual components of the stator cannot maintain their relative position during assembly and winding
Solution Approach 1:
The insulating lamina and cover lamina are designed with complementary form-fitting elements (protrusions and recesses) that automatically align and secure the components together during assembly, eliminating the need for additional fastening mechanisms and ensuring stable relative positioning without complex external connection structures
Solution Approach 2:
The connection function is integrated directly into the insulating and cover laminas by combining the form-fitting elements with the lamina structures themselves, creating a unified assembly where the connection mechanism and the components are merged into a single integrated unit
2Ease of manufacture
If simple structural measures are used for assembly, then the assembly process is easier, but the risk of component separation during winding increases
Solution Approach 1:
The form-fitting elements utilize curved or rounded geometric features that enable smooth insertion and secure engagement during assembly, allowing components to be easily joined while maintaining reliable connection that prevents separation during the winding process
Solution Approach 2:
The form-fitting elements are designed with nested geometric features where protrusions fit into recesses, creating a interlocking configuration that secures components together through nested structural elements that prevent separation while maintaining assembly simplicity
3Stability of the object's composition
If form-fitting connection elements are added to the insulating and cover laminas, then the relative position of components is maintained during assembly, but the manufacturing complexity of the laminas increases
Solution Approach 1:
The form-fitting elements are designed with optimized geometric parameters including appropriate dimensions, tolerances, and material properties that enable reliable connection while remaining compatible with standard manufacturing processes, balancing positioning stability with manufacturing feasibility
Solution Approach 2:
The form-fitting elements are strategically positioned at specific locations on the insulating and cover laminas where they provide maximum positioning stability with minimal impact on overall manufacturing complexity, concentrating the connection function at critical local points rather than requiring precision throughout the entire lamina
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
The design simplifies the assembly process by maintaining the relative position of stator components, reducing the risk of separation during winding and enabling efficient application of stator windings, particularly in skewed stators with obliquely running coil windings.
Implementation Method 1
The fixing bolt can be inserted into the recess with pressure, resulting in a frictional connection between the wall of the fixing bolt and the wall sections delimiting the recess
Implementation Method 2
In the case of a deformation of the fixing bolt - in particular in the embodiment of the insulating lamella including fixing bolts made of plastic - a form fit can also be produced in the axial direction by means of an undercut between the fixing bolt and the recess
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention concerns a stator for an electric machine, comprising a plate stack comprising a plurality of superposed stator plates, the plate stack being delimited at the ends by cover plates and an insulating plate being disposed on at least one cover plate in the plate stack, the insulating plate interlocking with the adjacent cover plate.