Stator Interconnection Board Axial Projections Terminal Plug Guidance
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Solution Overview
Problem
The production and installation of conductor elements in electric machines with single-tooth windings are complex due to the need for secure guidance of terminal plugs during connection, which is challenging and costly, especially when independent of the bearing shield.
Innovation Solution
The use of an interconnect plate with axial projections integrally formed on a plastics plate supports terminal plugs in all spatial directions, allowing easy and cost-effective production and installation, with conductor elements punched from metal sheets and bent to form sheet-metal lugs for insulation-displacement connections, and rivet pins for secure fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductor elements are produced and installed with secure guidance of terminal plugs, then connection reliability is improved, but production complexity and cost increase
Solution Approach 1:
The patent merges the terminal plug guidance function directly into the interconnect plate structure by integrating axial projections that extend through the plate thickness. This combines the support function with the interconnect plate itself, eliminating the need for separate guidance components and reducing production complexity while maintaining connection reliability
Solution Approach 2:
The axial projections serve as intermediary elements between the terminal plugs and the interconnect plate. These projections provide a mediating structure that guides and supports the terminal plugs during connection, ensuring proper alignment and secure guidance without requiring complex external fixtures or additional components
2Reliability
If terminal plugs are supported in all spatial directions, then guidance reliability is improved, but structural complexity increases
Solution Approach 1:
The patent applies local quality by creating axial projections with specific geometric features at precise locations on the interconnect plate. These projections have tailored shapes and positions that provide directional support exactly where needed, ensuring terminal plugs are guided in all spatial directions without requiring a completely complex structural redesign of the entire plate
3Ease of manufacture
If conductor elements are punched from metal sheets and bent, then manufacturing ease is improved, but precision of terminal plug positioning may worsen
Solution Approach 1:
The patent applies preliminary action by pre-forming the axial projections into the interconnect plate structure before conductor element installation. These projections are created in advance with precise dimensions and positions, establishing fixed reference points that guide terminal plug positioning. This preliminary structuring ensures manufacturing precision is maintained even though the conductor elements themselves are easily manufactured through punching and bending operations
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 provides reliable and efficient support for terminal plugs during installation, reducing complexity and cost by ensuring secure guidance and easy assembly, while accommodating axial forces and tolerances, and allowing for the connection of multiple phases with reduced parts and insulation.
Implementation Method 1
the conductor elements are preferably fastened to the plastics body by means of plastic material deformation of said plastics body
Data Source
AI summary
An interconnection board (52) of a stator (10) of an electrical machine (12), as well as a method for producing same, by means of which an electrical winding (16) of the stator (10) can be connected to customer-specific connecting plugs (56) for power supply, wherein the interconnection board (52) has a closed ring (61) as a plastic body (62), onto which closed ring (61) exactly three holding elements (63) are integrally formed, extending in the axial direction (3), in which holding elements respective axial connector plugs (54) made of metal extend in the axial direction, wherein the axial connector plugs (54) are each integrally configured with conductive elements (58) which can be directly electrically connected to connecting wires (30, 31) of the electrical winding (16).