Stator Interconnect Plate for Reliable Insulation-Displacement Connections
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Solution Overview
Problem
Existing stator designs for electrical machines face challenges in reliably pressing insulation-displacement clamps into receiving pockets without bending, leading to inconsistent electrical contact due to the axial stacking of contact rings.
Innovation Solution
The design incorporates an interconnect plate with annular metal conductor strips and insulation-displacement elements molded thereon, which are pressed axially into receiving pockets, ensuring reliable electrical contact and reduced susceptibility to bending, with centering pins for precise positioning and plastic deformation for secure fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation-displacement clamps are pressed axially into receiving pockets in stacked contact rings, then electrical contact with coils is achieved, but the clamps bend and tilt causing unreliable contact
Solution Approach 1:
The patent transitions from a stacked axial arrangement of multiple contact rings to a single-planar interconnect plate where all contact elements are positioned in essentially the same plane. This dimensional change eliminates the cumulative bending and misalignment issues that occur with axial stacking, as each insulation-displacement clamp is pressed into its receiving pocket without interference from adjacent stacked rings.
Solution Approach 2:
The patent merges multiple separate contact rings into a single integrated interconnect plate structure. By combining the functions of multiple stacked rings into one monolithic component, the design eliminates the instability caused by axial stacking while maintaining all necessary electrical connections to the coils.
2Reliability
If multiple contact rings are stacked axially to connect coils, then electrical interconnection is achieved, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The patent combines multiple separate contact rings into a single integrated interconnect plate, reducing the number of discrete components from multiple rings to one unified structure. This merging simplifies the overall device complexity while maintaining all necessary electrical connection functions.
Solution Approach 2:
The interconnect plate serves multiple functions simultaneously: it provides electrical interconnection between all coils, maintains precise positioning of insulation-displacement clamps, and eliminates the need for axial stacking. This multi-functionality in a single component reduces both device complexity and assembly steps.
3Ease of manufacture
If insulation-displacement clamps are pressed into receiving pockets, then electrical contact is made, but the clamps may tilt and fail to make reliable contact
Solution Approach 1:
By positioning all receiving pockets and insulation-displacement clamps in essentially the same plane rather than stacking them axially, the patent ensures that each clamp can be pressed into its pocket without tilting or bending. This planar arrangement guarantees precise positioning and reliable contact formation during manufacturing.
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 solution enables reliable and defined insulation-displacement connections, reducing the risk of short circuits and ensuring stable electrical contact even under varying conditions, making the stator suitable for robust use in motor vehicles.
Implementation Method 1
the fork contact of the insulation-displacement clamp engages around the winding wire in the receiving pocket and cuts into the winding wire in order to produce an electrical contact
Implementation Method 2
centering pins which extend in the axial direction are molded onto the insulating lamination. Accordingly, centering openings in which the centering pins engage axially are formed in the axial direction on the interconnect plate
Implementation Method 3
the free ends of the centering pins can be deformed plastically in order to form a form-fitting connection
Data Source
AI summary
Stator and method for producing a stator for an electrical machine, comprising a stator main body (34) which has radial stator teeth (14) for receiving coils (17) of an electrical winding and, on an end side of the stator main body (34), has an insulating lamination (40) with receiving pockets (46) for insulation-displacement terminal elements (70), wherein the coils (17) are wound by means of a winding wire which is inserted into the receiving pockets (46), wherein an interconnection plate (52) has annular conductors (84) on which in each case a plurality of insulation-displacement terminal elements (70) are arranged, which insulation-displacement terminal elements axially engage into the receiving pockets (46) in order to make electrical contact with the winding wire, wherein the interconnection plate (52) is manufactured from plastic and has annular grooves (59) which are open axially at the bottom and into which the annular conductors (84) are inserted.