Stator Connection Ring Interlock for Vibration-Resistant Assembly
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Solution Overview
Problem
Existing stators for electric machines, particularly in industrial and automotive applications, face challenges in assembly complexity and operational reliability due to high positioning accuracy requirements and vibration-induced stress on connector terminals and connection rings.
Innovation Solution
A stator design featuring a ring-shaped or ring-segment-shaped plastics body connection ring with interlocking means, such as trapezoidal sections, that securely connect with a connector terminal, allowing for simplified assembly and vibration absorption, ensuring precise positioning and reduced stress on weld points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connector terminals are used without interlocking means, then assembly is simpler, but positioning accuracy and operational reliability deteriorate due to vibrations
Solution Approach 1:
The interlocking means create a mechanically locked connection between the connector terminal and connection ring, establishing a stable, vibration-resistant interface that maintains electrical contact reliability under dynamic operating conditions
Solution Approach 2:
The interlocking means act as an intermediary mechanical structure that couples the connector terminal to the connection ring, providing both positioning accuracy and vibration absorption while maintaining electrical connectivity
2Measurement precision
If high positioning accuracy is required for connector terminals, then operational reliability improves, but manufacturing precision requirements and assembly difficulty increase
Solution Approach 1:
The interlocking means provide self-aligning mechanical engagement features that automatically establish the correct positional relationship between connector terminal and connection ring, reducing dependence on tight manufacturing tolerances
Solution Approach 2:
The interlocking means enable self-positioning and self-alignment during assembly, where the mechanical features guide the connector terminal into its correct position on the connection ring without requiring external positioning fixtures or high-precision machining
Data Source
AI summary
A stator for an electric machine having a winding and a connection ring which can be placed axially on the winding and is intended for connecting the winding of the stator. The connection ring has a ring-shaped or ring-segment-shaped plastics body with at least three conductors which are each associated with a phase and are interconnected, and the ends of at least some of the conductors protrude axially beyond the winding. The connection ring has a connector terminal which can be interlockingly connected to the ring and which has at least three electrical connector portions. When the connection ring and the connector terminal are joined together, each contact a conductor of the connection ring that is associated with a phase and each electrically conductively connect to a connector of the connector terminal by the connection ring and the connector terminal having interlocking structure which define a defined position of the connection ring and the connector terminal relative to one another.