Stator Interconnection Module for Compact End-Winding Layout
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Solution Overview
Problem
Conventional stator arrangements for electric motors have large inner diameters due to wire routing through annular regions, leading to material inefficiency and poor thermal response for heat dissipation.
Innovation Solution
A stator arrangement with a separate interconnection module positioned on the end side of the stator, featuring integral electrical terminal conductors embedded in an insulating material, which decouples the interconnection from the stator winding and eliminates the need for bridging wire guides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire routing is performed through annular regions of end plates, then electrical interconnection between poles is achieved, but the inner diameter increases and material consumption increases
Solution Approach 1:
The patent extracts the wire routing function from the annular region of the end plate and relocates it to the stator teeth. The winding wire is guided through grooves on the stator teeth surface, eliminating the need for annular wire routing channels. This extraction reduces material consumption while maintaining electrical interconnection reliability.
Solution Approach 2:
The patent changes the routing dimension from the annular plane (end plate region) to the radial/axial dimension (stator teeth surface). By utilizing the grooves on the stator teeth, the wire routing moves from a two-dimensional annular path to a three-dimensional path along the teeth, reducing the required inner diameter and material consumption.
2Reliability
If wire routing is performed through annular regions of end plates, then electrical interconnection between poles is achieved, but axial length increases
Solution Approach 1:
The patent extracts the wire routing function from the annular region and relocates it to the stator teeth grooves. This eliminates the need for deep annular channels that would increase axial length, achieving electrical interconnection with minimal axial dimension.
Solution Approach 2:
Instead of routing wires through the annular region (conventional approach), the patent inverts the approach by routing wires along the stator teeth surface. This inversion reduces the axial length requirement while maintaining reliable electrical interconnection.
3Productivity
If continuous wire is wound along stator teeth to form poles, then winding efficiency is improved, but thermal response deteriorates
Solution Approach 1:
The patent segments the continuous wire winding into discrete sections that are separately connected to individual stator teeth. The winding wire is inserted into grooves on each stator tooth and connected separately, rather than forming continuous loops. This segmentation improves thermal response by reducing heat accumulation while maintaining winding efficiency through automated insertion processes.
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 achieves compact dimensions with minimal axial length, reduces material consumption, and enhances thermal response by simplifying production and allowing for quicker, automated manufacturing suitable for mass production.
Implementation Method 1
The stator has a stator winding by means of which a time-variable magnetic field is induced by means of a time-variable current flow
Implementation Method 2
the terminal conductors each form a terminal contact to which an external power supply and/or control of the stator arrangement can be connected and a winding contact which is electrically conductively connected to a winding wire end
Data Source
AI summary
A stator arrangement for an electric machine has a stator and an interconnection module. The stator includes a stator core on which a stator winding is arranged. The interconnection module electrically interconnects winding wire ends of the stator winding. The interconnection module is positioned on the stator on an end side. The interconnection module includes integral electrical terminal conductors which are embedded at least partially in a body of an electrically insulating material. The terminal conductors each form a terminal contact to which an external power supply and/or control of the stator arrangement can be connected, and a winding contact which is electrically conductively connected to a winding wire end.