Stator Interconnection End Disk for Electric Motor
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Solution Overview
Problem
Existing stator devices for electric motors face challenges in assembly and manufacturing due to complex terminal formations, leading to inefficiencies, increased installation space requirements, and risks of malfunction and defects, especially in thermally or vibration-stressed environments.
Innovation Solution
Integration of interconnection rings into a hollow-cylindrical interconnection end disk with a ring-shaped deflection disk and deflection pins, allowing for accurate guiding of winding wires to welding hooks without tension and preventing crossings, enabling automated and reliable assembly and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex terminal formations are used to interconnect multiple windings, then the electrical connection reliability is improved, but the device complexity and manufacturing complexity increase significantly
Solution Approach 1:
The patent merges multiple separate terminal formations and interconnection elements into a single integrated terminal block. This consolidation maintains all necessary electrical connections while eliminating the complexity of multiple discrete terminals, directly resolving the contradiction between connection reliability and device complexity.
Solution Approach 2:
The terminal block serves multiple functions simultaneously: it provides electrical interconnection for multiple windings, enables automated assembly through standardized interfaces, and simplifies the overall structure. This multi-functionality allows a single component to replace what would otherwise require multiple separate elements, reducing complexity while maintaining reliability.
2Reliability
If complex terminal formations with multiple interconnection elements are used, then the electrical connection capability is improved, but the manufacturing efficiency decreases and productivity is reduced
Solution Approach 1:
The terminal block is pre-assembled with all necessary electrical connections and interconnection elements before installation. This preliminary preparation allows for automated assembly in the main production line, significantly improving manufacturing efficiency while maintaining the required electrical connection capability.
Solution Approach 2:
By combining multiple terminal functions into a single integrated block, the patent reduces the number of assembly steps required. This consolidation enables more efficient automated manufacturing processes, directly addressing the productivity issue while preserving electrical connection reliability.
3Reliability
If traditional terminal arrangements are used for multiple windings, then the electrical interconnection is achieved, but the installation space required increases significantly
Solution Approach 1:
The terminal block design nests multiple electrical connection points and interconnection elements within a compact three-dimensional structure. This nested arrangement allows all necessary electrical interconnections to be achieved within a minimal installation footprint, directly resolving the contradiction between electrical interconnection capability and installation space requirements.
4Adaptability or versatility
If wire ends are led out separately for each winding, then the electrical connection flexibility is improved, but the risk of abrasion points and defects increases in thermally or vibration-stressed environments
Solution Approach 1:
The terminal block merges multiple separate wire end connections into a single protected structure. This consolidation reduces the number of exposed wire ends and potential abrasion points, while the integrated design provides mechanical protection against thermal and vibrational stresses, thereby improving reliability while maintaining connection flexibility.
5Manufacturing precision
If complex manual assembly processes are used for terminal formations, then the assembly accuracy can be controlled, but the automation capability is lost and manufacturing time increases
Solution Approach 1:
The terminal block is pre-assembled with all electrical connections precisely established before installation into the motor. This preliminary precision assembly can be performed under controlled conditions, and then the complete terminal block is installed as a single unit, enabling automation while maintaining high assembly accuracy.
Solution Approach 2:
By merging all terminal connections into a single integrated block with standardized interfaces, the patent enables automated handling and installation equipment to be used. This consolidation maintains assembly precision through precise manufacturing of the integrated structure while fully enabling automation capability.
Data Source
AI summary
A stator device with a plurality of windings, on a winding carrier, that electromotive interaction with a rotor. The windings are parallel to one another and to the center axis. The windings can be individually electrically contacted with winding terminals of a winding wire. The windings are assigned to at least two disk-shaped and/or ring-shaped electrically conductive interconnection rings so that they are electrically insulated from one another. The winding terminals are connected using the interconnection ring assigned to this terminal polarity (U; V; W) for external permanent common contact by welding hooks formed on the radial inner side on the interconnection ring. A ring-shaped deflection disk, with deflection pins, is provided in the axial direction on the interconnection end disk.